Device and method for coating surfaces

ABSTRACT

The present invention relates to devices and methods for coating surfaces including surfaces of medical devices, in particular the coating of microprojections on microprojection arrays. The present invention also relates to print head devices and their manufacture and to methods of using the print head devices for manufacturing articles such as microprojection arrays as well as to coating the surfaces of microprojection arrays. The present invention also relates to high throughput printing devices that utilize the print heads of the present invention.

1. BACKGROUND OF THE INVENTION

The present invention relates to devices and methods for coatingsurfaces including surfaces of medical devices, in particular thecoating of microprojections on microprojection arrays. The presentinvention also relates to print head devices and their manufacture andto methods of using the print head devices for manufacturing articlessuch as microprojection arrays as well as to coating the surfaces ofmicroprojection arrays. The present invention also relates to highthroughput printing devices that utilize the print heads of the presentinvention.

2. DESCRIPTION OF THE PRIOR ART

The reference in this specification to any prior publication (orinformation derived from it), or to any matter which is known, is not,and should not be taken as an acknowledgment or admission or any form ofsuggestion that the prior publication (or information derived from it)or known matter forms part of the common general knowledge in the fieldof endeavour to which this specification relates.

In recent years, attempts have been made to devise new methods ofdelivering drugs and other bioactive materials, for vaccination andother purposes, which provide alternatives that are more convenientand/or enhanced in performance to the customary routes of administrationsuch as intramuscular and intradermal injection. Limitations ofintradermal injection include: cross-contamination through needle-stickinjuries in health workers; injection phobia from a needle and syringe;and most importantly, as a result of its comparatively large scale andmethod of administration, the needle and syringe cannot target key cellsin the outer skin layers. This is a serious limitation to many existingand emerging strategies for the prevention, treatment and monitoring ofa range of untreatable diseases. There is also a need to reduce theamount of material delivered due to toxicity of the material or due tothe need to conserve the material because it is difficult or expensiveto produce.

In an effort to solve some of the issues referenced abovemicroprojection arrays or microneedle arrays have been utilized todeliver various materials through the skin. For example, WO 2005/072630describes devices for delivering bioactive materials and other stimulito living cells. The devices comprise a plurality of projections whichcan penetrate the skin so as to deliver a bioactive material or stimulusto a predetermined site. The projections can be solid and the deliveryend of the projection is designed such that it can be inserted intotargeted cells or specific sites on the skin. Other devices utilizingmicroprojections and/or microneedles either solid or biodegradable aredescribed in

One of the challenges of using devices that contain microneedles and/ormicroprojections is the need to coat the projections. Various coatingtechniques such as dipping the array into a coating solution or sprayingthe coating onto the projections have been described. For example, Gilland Prausnitz, J. Controlled Release (2007), 117: 227-237 describecoating microprojections by dipping the microprojections into a coatingsolution reservoir through dip holes that are spaced in accordance withthe microprojection array. Cormier et al., J. Controlled Release (2004),97: 503-511 describe coating microneedle arrays by partial immersion inan aqueous solution containing active compounds and polysorbate. WO2009/079712 describes methods for coating microprojection arrays byspray coating the microprojections and drying the sprayed solution withgas.

Inkjet printing has been used to deposit pharmaceutical compositions ona variety of devices and media. For example Wu et al., (1996) J.Control. Release 40: 77-87 described the use of inkjets to creatingdevices containing model drugs; Radulescu et al. (2003) Proc. WinterSymposium and 11^(th) International Symposium on Recent Advance ins DrugDelivery Systems described the preparation of small diameterpoly(lactic-co-glycolic acid) nanoparticles containing paclitaxel usinga piezoelectric inkjet printer; Melendez et al. (2008) J. Pharm. Sci.97: 2619-2636 utilized inkjet printers to produce solid dosage forms ofprednisolone; Desai et al. (2010) Mater. Sci. Eng. B 168: 127-131 used apiezoelectric inkjet printer to deposit sodium alginate aqueoussolutions containing rhodamine R6G dye onto calcium chloride surfaces;Sandler et al. (2011) J. Pharm. Sci. 100: 3386-3395 used inkjet printingto deposit various pharmaceutical compounds on porous paper substrates;Scoutaris et al. (2012) J. Mater. Sci. Mater. Med. 23: 385-391 describedthe use of inkjet printing to create a dot array containing twopharmacological agents and two polymers. Inkjet printing has also beenused to deposit various pharmaceutical compositions on stents (Tarcha,et al. (2007) Ann. Biomed. Eng. 35: 1791-1799). Recently, piezoelectricinkjet printers have been used to coat microneedles. Boehm et al. (2014)Materials Today 17(5): 247-252 has described the use of inkjet printersto coat microneedles prepared from a biodegradable acid anhydridecompolymer which contains alternating methyl vinyl ether and maleicanhydride groups with miconazole.

Spotting of DNA microarrays is achieved traditionally using acomputer-controlled xyz motion stage with a head carrying a pen deviceto pick up small drops of solution from the multiwell plates fortransfer and spotting them onto a surface. These spotting pens aresophisticated designs adapted from the quill type of ink pen. The penprinting is reliable and repeatable when using a flat solid surfacesubstrate. Problems can arise with the contact technology when usinguneven and membrane types of substrates. The uneven substrates canresult in missed spots when the surface regions are lower than the levelof a pen or pens within a bank of printing pens. Spotting onto membranescan result in unacceptable surface indentations and uneven spotting ifthe membrane absorbs the spotting solution too quickly. Otherdisadvantages include the limited range of volume control for each spotprinted and the inability to overprint without the risk of crosscontamination of the spotted fluids. The design of all the currentjetting and printing platforms have a movable gantry above the workingsurface, which will be deleterious for aseptic or GMP manufacturebecause of particulate generation above the work surface.

Positive pressure displacement is another spotting method that utilizesa syringe system or valve jet for deposition of the fluids. In valve-jettechnology an orifice or nozzle is attached to a solenoid valve thatopens and shuts rapidly to produce streams of intermittent droplets froma pressurized flow. A syringe system picks up the fluid from samplewells and then dispenses the fluid onto the substrate using positivedisplacement. These systems are highly reliable, as the fluidic propertyinfluence on dispensing is less than the effect on piezoelectricmicrodispensing. However, these positive pressure displacementmicrodispensing systems can have lower repeatability rates whendispensing at their lower volume capabilities. The low-end depositionvolumes for these systems are in the nanoliter range.

In drop-on-demand piezoelectric microdispensing devices, the fluid ismaintained at ambient pressure and a piezoelectric transducer is used tocreate a drop only when needed. The transducer creates a volumetricchange in the fluid resulting in pressure waves. The pressure wavestravel to the orifice, are converted to fluid velocity which results ina drop being ejected from the orifice. Alternatively, the piezotransducer establishes an acoustic pulse which alters the fluid meniscusprofile at the orifice.

As a non-contact printing process, the accuracy of ink-jet dispensing isnot affected by how the fluid wets a substrate, as is the case ofpositive displacement or pen transfer systems “touching off” the fluidonto the substrate during the dispensing event. Thus, the fluid sourcecannot be contaminated by fluid already on the substrate or by thesubstrate material. Therefore, it is possible to overprint spots using adifferent reagent or biofluid without the risk of cross contamination.Finally, the ability to free-fly the droplets of fluid over a millimeteror more allows fluids to be dispensed into wells or other substratefeatures.

The current inkjet systems used to coat medical devices includingmicroprojection arrays utilize an XYZ gantry system for positioningeither single nozzles, or arrays of individually addressable nozzleswhich then deliver the coating over the microprojections. The print headis rastered across the target substrate which involves the accelerationand de-acceleration of the axis for each line that is printed. Ascommercially available print heads do not match the spacing ofmicroprojection arrays, the print head must be sabred (i.e. Located atan angle) and have variable timing on the ejection of drops in order toleverage the speed increase available when using multiple nozzles. Witha single nozzle, the raster movement is time-consuming and is asignificant factor for small substrates where the movement consumes upto 50% of the time required to coat the microprojection array. Forexisting nozzle arrays, variable data must be used in order to achievethe desired result, which increases the system complexity and hencecost. There exists a need for new devices and methods to coat substratesincluding medical device substrates such as microprojection arrays whichare less expensive, less complex, more accurate and efficient. There isalso the need for these devices to be aseptic such that there is nocontamination of the product being coated. Presently there are nosystems for dispensing materials onto surfaces that have been designedspecifically for commercial pharmaceutical grade manufacture.

3. SUMMARY OF THE PRESENT INVENTION

The present invention relates to devices and methods for coatingsurfaces including surfaces of medical devices, in particular thecoating of microprojections on microprojection arrays. The presentinvention also relates to print head devices and their manufacture andto methods of using the print head devices for manufacturing articlessuch as microprojection arrays as well as to coating the surfaces ofmicroprojection arrays. The present invention also relates to highthroughput devices that utilize the print heads of the present inventionto produce a large number of coated substrates including microprojectionarrays. In a general sense the present invention relates to devices andmethods for depositing materials onto substrates. The devices andmethods of the present invention can be used to print or coat or coveror deposit materials, in particular fluid materials onto substrates. Thedevices and methods of the present invention can be used to coat fluidsonto substrates such as coating a stent or coating the microprojectionsof a microprojection array. The present invention relates to devices forprinting or coating of fluids including pharmaceuticals and biologicalmaterials onto microprojection arrays which may provide improvedefficiency and precise coating of three dimensional substrates. Thedevices of the present invention provide simultaneous two dimensiondeposition of pharmacological grade biological material in an asepticenvironment. These printing devices provide for the coating of differentantigens on different microprojections of a microprojection array. Thedevices of the present invention can also deposit different antigens anddifferent adjuvants or excipients on any microprojection on amicroprojection array. Such biological fluids include vaccines andbiopharmaceuticals which pose an additional challenge for coating inthat the active material may only be available in low concentrationssuch as 1-10 mg/ml. This in turn may require that multipleadministrations of the material with drying time in betweenadministrations of the material on each feature in order to achieve thetargeted therapeutic dose. As the total fluid delivered may berelatively high (the number of drops) it is important to efficientlydeposit the material so that the total time to coat the substrate is notexcessive.

Ink jet coating of a microprojection array patch and other vaccine andbiological platforms allows for precise dosing and allocation ofbiologics targeting each individual projection on the platform with acontrolled dose. Typically, a microprojection array platform has alength and width of less than 20 mm and carries an evenly spacedtwo-dimensional array of projections. The number of projection in eachdirection is typically less than 100 and therefore the density ofprojections on the array is between 2000 and 10000 projections per cm².The amount of material needed for an effective dose is typically about500 to 1000 picoliters per projection. Currently available printertechnology is not made to print pharmaceutical grade material nor cancurrent technology print with the accuracy required to provide theappropriate amount of material on each projection. Commerciallyavailable multi-nozzle printer heads are designed for document andgraphic printing where the focus is on variable data addressability,high DPI in one dimension and small drop size (typically less than 30picoliters). These characteristics do not fit the requirements necessaryto produce inkjet coating of microprojection arrays. Moreover,commercial print heads do not provide cooling and mixing functions whichpermit biological materials to remain stable during the coating process.

In a first broad form the present invention provides a device forcoating a substrate, the device including: a pumping chamber; a nozzleplate; a piezoelectric actuator; and a membrane plate.

In a second broad form the present invention provides a device forcoating a substrate, the device including: a pumping chamber wherein afluid is contained; a nozzle plate attached to the pumping chamberwherein the nozzle plate comprises a plurality of nozzles for dispensingthe fluid; a membrane plate; a piezoelectric actuator wherein theactuator pushes against the membrane plate such that the fluid isdispensed through the nozzles.

Typically the piezoelectric actuator is a piezoelectric stack actuator.

Typically the piezoelectric actuator is a piezoelectric unimorphactuator.

The device further comprising a device for mixing the fluid.

The device further comprises a housing.

The housing of the device may contain a cooling device.

The pumping chamber plate further comprises one or more fluid ports bywhich the fluid is pumped into the pumping chamber.

Typically the nozzle plate has multiple fluid ports.

Typically the nozzles are made of etched silicon.

Typically the nozzles are made of electroformed nickel.

Typically the nozzles are made of EDM stainless steel.

Typically the nozzles are made of mechanically punched stainless steel.

Typically the nozzles are made of laser-drilled stainless steel.

Typically the nozzles are made in a two dimensional array.

Typically the nozzle diameter is from about 30 μm to 200 μm.

Typically the number of nozzles in the two dimensional array is between100 to 5000.

Typically the number of nozzles in each dimension is identical.

Typically the spacing between the nozzles is from about 80 to about 800micrometers.

Typically each nozzle dispenses about 30 to 3000 picoliters of fluid.

Typically the nozzles are coated to increase durability.

Typically the nozzles are coated to increase hydrophobicity.

Typically the fluid is a biological material.

Typically the fluid is a vaccine.

Typically the pumping chamber is moulded.

Typically the device is pre-primed with a priming solution.

Typically the membrane plate is made of stainless steel.

Typically the device is aseptic.

Typically the nozzles are aseptic.

Typically the device is disposable.

Typically the nozzle plate is disposable.

Typically the pumping chamber is disposable.

Typically the biological fluid is kept in a sterile condition.

Typically the vaccine is kept in a sterile condition.

In a third broad form the present invention provides a method forcoating a microprojection array the method including: aligning thedevice of claim 1 over a microprojection array comprising a plurality ofmicroprojections such that each nozzle is aligned over amicroprojection; and activating the actuator such that the membraneplate pushes fluid through the nozzles and onto the microprojectionsthereby coating the microprojection array.

In a fourth broad form the present invention provides a method forcoating microprojections on a microprojection array to a predeterminedvolume, the method including: aligning the device of claim lover amicroprojection array comprising a plurality of microprojections suchthat each nozzle is aligned over a microprojection; activating theactuator such that the membrane plate pushes fluid through the nozzlesand onto the microprojections; and repeating the previous step such thatthe microprojections are coated to the predetermined volume.

In a fifth broad form the present invention provides a method forcoating microprojections on a microprojection array the methodincluding: aligning the device of claim 1 over a microprojection arraycomprising a plurality of microprojections such that each nozzle isaligned over a first set of microprojections that are uncoated;activating the actuator such that the membrane plate pushes fluidthrough the nozzles and onto the first set of microprojections such thatthe microprojections are coated; moving the microprojection arrayrelative to the device such that the nozzles are aligned over a secondset of microprojections that are uncoated; and activating the actuatorsuch that the membrane plate pushes fluid through the nozzles and ontothe second set of microprojections such that the microprojections arecoated.

Typically the nozzles are from about 50 to about 2000 micrometers fromthe microproj ections.

Typically the alignment of the device over the microprojection array isaccomplished by utilizing a camera.

In a sixth broad form the present invention provides a method forcoating microprojections on a microprojection array method including:aligning the device of over a microprojection array comprising aplurality of microprojections such that each nozzle is aligned over afirst set of microprojections that are uncoated; activating the actuatorsuch that the membrane plate pushes a first fluid through the nozzlesand onto the first set of microprojections such that themicroprojections are coated; moving the microprojection array relativeto the device such that the nozzles are aligned over a second set ofmicroprojections that are uncoated; and activating the actuator suchthat the membrane plate pushes a second fluid through the nozzles andonto the second set of microprojections such that the microprojectionsare coated.

In a seventh broad form the present invention provides a method forcoating microprojections on a microprojection array the methodincluding: the device of claim 1 over a microprojection array comprisinga plurality of microprojections such that each nozzle is aligned over amicroprojection; activating the actuator such that the membrane platepushes a first fluid through the nozzles and onto the microprojections;and activating the actuator such that the membrane plate pushes a secondfluid through the nozzles and onto the microprojections.

In an eighth broad form the present invention provides a device forcoating the one or more of the microprojections on a microprojectionarray the device including: a housing; a piezoelectric actuator; arestrictor plate; a membrane plate; a pumping chamber; a descenderplate; a nozzle plate; wherein the piezoelectric stack actuator isoperably linked to the membrane plate such that when the piezoelectricstack actuator is activated the piezoelectric stack actuator pushes themembrane plate.

Typically one or more ports attached to the pumping chamber.

The device may further comprise a second restrictor plate.

In a ninth broad form the present invention provides a device forcoating the one or more of the microprojections on a microprojectionarray the device including: a housing coupled to a pumping chamber whichis attached to a descender plate which is attached to a nozzle platewherein between the housing and the pumping chamber is a stackpiezoelectric actuator operably linked to a membrane plate such thatwhen the piezoelectric stack actuator is activated the piezoelectricstack actuator pushes the membrane plate.

Typically one or more ports attached to the pumping chamber.

The device may further comprise a second restrictor plate.

In a tenth broad form the present invention provides a device forprinting material on to a substrate the device including: a top platecomprising a single inlet hole and a single outlet hole attachablylinked to a fluid distribution plate comprising one or more reservoirsattachably linked to a piezoelectric membrane plate comprising apiezoelectric device and a membrane below the piezoelectric devicewherein the membrane is deformed when the piezoelectric device isactivated, the piezoelectric membrane plate attachably linked to apiezoelectric deformation clearance plate which is attachably linked toa pumping chamber plate which is attachably linked to a nozzle platecomprising nozzles from which the fluid material can be expelled ontothe substrate.

Typically the top plate, fluid distribution plate, piezoelectricmembrane plate, piezoelectric deformation clearance plate, pumpingchamber plate and nozzle plate are all contained within a housing.

Typically the nozzle plate is from about 200 to 500 μm thick.

Typically the pumping chamber is less than 1 mm in thickness

Typically the nozzle geometry of the nozzles in the nozzle plate iscontinuous and has no singular points.

Typically the pumping chamber plate has venting holes.

Typically the nozzle plate has venting holes.

Typically the nozzle plate venting holes are connected to the pumpingchamber plate venting holes.

Typically the venting holes are less than or equal to 50 μm in diameter.

Typically the pumping chamber plate has two restrictors.

Typically the nozzle plate is comprised of two plates including adescender plate.

In an eleventh broad form the present invention provides a single printhead coating device the device including: X, Y translational stage onwhich microprojection arrays can be mounted; a fiducial camera with LEDlight; a Z stage to which a rotational print head is attached.

The print head coating device may further comprise a base to which thestage is attached.

Typically the translational stage has a positional accuracy of +/−1 μm.

Typically the translational stage can travel of speeds up to 500 mm/s.

Typically the translational stage has an acceleration of up to 5000mm/s².

It will be appreciated that the broad forms of the invention and theirrespective features can be used in conjunction, interchangeably and/orindependently, and reference to separate broad forms is not intended tobe limiting.

4. BRIEF DESCRIPTION OF THE DRAWINGS

Various examples and embodiments of the present invention will now bedescribed with reference to the accompanying drawings, in which:

FIG. 1 is an exploded schematic front view of one embodiment of theprint head device of the present invention.

FIG. 2 is an exploded schematic partial side view of one embodiment ofthe print head device of the present invention.

FIG. 3 is an exploded schematic front view of one embodiment of theprint head device of the present invention.

FIG. 4 is an exploded schematic partial side view of one embodiment ofthe print head device of the present invention.

FIG. 5 is an exploded schematic front view of one embodiment of theprint head device of the present invention.

FIG. 6—is an exploded schematic partial side view of one embodiment ofthe print head device of the present invention.

FIG. 7A is a diagram of one embodiment of the pumping chamber; 7B—Adiagram of one embodiment of the pumping chamber.

FIG. 8 is a schematic diagram of one embodiment of the nozzle plate.

FIG. 9 is a schematic diagram of one embodiment of the piezoelectricstack actuator.

FIG. 10A is a side view of one embodiment of the assembled print head;10B—rotated side view of one embodiment of the assembled print head.

FIG. 11 is a schematic of one embodiment of the print head device of thepresent invention.

FIG. 12 is a schematic of one embodiment of the restrictor plate in theprint head device of the present invention.

FIG. 13 is a schematic isometric view of one embodiment of the printhead of the present invention.

FIG. 14A is a schematic isometric view of one embodiment of the printhead of the present invention; 14B—A schematic bottom view of oneembodiment of the print head of the present invention; and 14C—Aschematic side view of one embodiment of the print head of the presentinvention.

FIG. 15A is a schematic side view of one embodiment of the print head ofthe present invention; and 15B—A schematic top view of one embodiment ofthe print head of the present invention.

FIG. 16A is a photograph of one embodiment of the nozzle plate; 16B—highmagnification photograph of the back side of one embodiment of thenozzle plate; 16C—high magnification photograph of the front side of oneembodiment of the nozzle plate; 16D—schematic drawing of one embodimentof the interaction between the nozzle plate and the descender plate.

FIG. 17 shows one embodiment of the print head of the present invention.

FIG. 18A is a top view of the pumping chamber plate of one embodiment ofthe pumping chamber plate; FIG. 18B is a top view of the assembly of oneembodiment of the pumping chamber plate; and FIG. 18C is a detailed viewof one portion of the pumping chamber which has a sharpened edge thatcreates a pinning point for the moving line contact to retards the speedof the edge of the moving contact line.

FIG. 19A is a top view of the plate assembly showing the venting holesand FIG. 19B is a top view of the nozzle plate showing the ventingholes.

FIG. 20A-C is a sequential view of filling the chamber.

FIG. 21 is a diagram of one embodiment of a weight check function.

FIG. 22A is a schematic representation of a nozzle geometry with adiscontinuous internal profile having a singular point; FIG.22B—schematic representation of a nozzle geometry with a discontinuousinternal profile having two singular points and FIG. 22C—schematicrepresentation of a nozzle geometry with a continuous internal profileand no singular points.

FIG. 23A is a schematic representation of a nozzle plate and descenderplate geometry with a discontinuous internal profile having a singularpoint and FIG. 23B—schematic representation of a nozzle plate anddescender plate geometry with a continuous internal profile having nosingular points.

FIG. 24A is a schematic representation of a nozzle plate and descenderplate geometry with a continuous internal profile having no singularpoints and 24B—photograph of a nozzle plate and descender plate geometrywith a continuous internal profile having no singular points.

FIG. 25 shows one embodiment of the meniscus oscillation waveform.

FIG. 26 is a diagram of a one embodiment of a PZT driver based on anamplifier.

FIG. 27 is a diagram of a one embodiment of a PZT driver based on anamplifier.

FIG. 28 is a diagram of one embodiment of a PZT signal feedback design.

FIG. 29 is a diagram of one embodiment of a single print head high speedcoating device.

FIGS. 30A to 30C shows an embodiment with a cohesive design featuringout-of-plane plane insertion dove tail connectors for the mat cohesion;the dove tail.

FIGS. 31A and 31B shows an embodiment with a cohesive design featuringout-of-plane plane insertion connectors for the mat cohesion, and crossshaped ended spigot to stack the mats.

FIGS. 32A and 32B shows an embodiment with a cohesive design featuringin-plane friction fit connectors for the mat cohesion, and cross shapedended spigot to stack the mats.

FIGS. 33A and 33B shows an embodiment with a strong cohesion of the matsin a compact stack is achieved with a hexagon shape and through spigots.

FIG. 34A to 34C shows an embodiment without guiding shaft (spigot), herewith in-plane friction fit connectors.

FIG. 35A-C shows various orientations of a patch embodiment that buttstogether to form a mat.

FIG. 36 shows one embodiment of a patch mat with 100 patches.

FIG. 37A shows a representation of a single column of two stackedpatches.

FIG. 37B shows a cross-section view of ten columns of five stackedpatches in a mat.

FIG. 38 is a schematic representation of one embodiment of the printhead with an integrated fluid reservoir which is contained within acover.

FIG. 39 is a schematic representation of one embodiment of the printhead with an integrated fluid reservoir.

FIG. 40A is a front view of a bio-processing bag fluid reservoir of oneembodiment of the integrated fluid reservoir.

FIG. 40B is a side view of a bio-processing bag fluid reservoir of oneembodiment of the integrated fluid reservoir.

FIG. 41 is a schematic representation of the lower section of theintegrated fluid reservoir embodiment of the print head.

FIG. 42 is a schematic representation of one embodiment of the printerconnection.

FIG. 43 is a schematic representation of one embodiment of an externalfluid reservoir in which feed lines extend from the print head to theexternal reservoir.

FIG. 44 is a schematic representation of one embodiment of an externalfluid reservoir in which feed lines extend from the print head to theexternal reservoir which provides a stirring mechanism.

FIG. 45 is a schematic diagram of an embodiment of a system forcontrolling operation of the print head.

5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Micro Array Projections or Micro Array Patches (MAP's) ormicroprojection array patches encompass a large number of disparatedevices which are currently in development. Other terms for thesedevices include microneedle arrays, microprojection patches andmicroneedle patches. These patches can be an alternative to theadministration of vaccines and other pharmacological substances viadermal or intramuscular injections by providing a method in which thesubstances are administered through the outer layer of the skin. Thepatches take a variety of forms from metal formed patches to polymermolded patches to patch projections formed from the vaccine orpharmacological solution itself. The manufacture of these patches relieson the ability to deposit a dried down drug solution or vaccine onto thetips of the microprojections with high throughput and high accuracy.Accurately coating the projections is important as the delivery of thecoated material to the patient needs to be consistent. If too littlematerial is delivered the efficacy of the treatment is compromised. Toomuch material could lead to overdosing or at a minimum wasting expensivevaccine or drug. The ability to coat the patches quickly is necessary toproducing a commercial product. Manufacturing of patches, regardless ofthe methodology involved, must be performed according to pharmaceuticalguidelines (e.g. PIC's code of GMP). Complete process control isrequired to satisfy both manufacturers and regulators that productquality is well understood and controlled at all times and productoutput is 100% monitored for non-conforming product and performancetrends. High speed high accuracy deposition on a large scale under theconditions required for aseptic manufacture has thus far proved elusivefor prior art coating processes. Methods for verification of the processoutput at high coating speeds have yet to be addressed by the industry.As an example, regulators will expect to see Process AnalyticalTechnology (PAT) which has the following critical quality attributes: 1)the mass/ volume of dispensed material is measured; 2) uniformity ofcoating across the substrate is maintained; 3) position of coating onprojections is verified; 4) non-conforming product is identified andremoved and 5) print head performance is monitored (drop size, dropposition, array uniformity).

Commercial inkjet printing systems are not made from biocompatiblematerials, do not follow GMP guidelines and do not require the samelevel of process control and performance verification that are requiredfor printing pharmaceutical or biological material. The devices andmethods of the present invention relate to an integrated control systemthat uses novel print head and nozzle plate design and manufacture,novel process control, novel PZT driving waveforms and inventive processsteps that ensure process control and quality output is maintained atall times. The methods and devices of the present invention include adesign for a coating system that will be acceptable for the manufactureof combination medical devices to be labelled as aseptically sterile,and provide a control system that will conform to the standards providedby global regulatory bodies.

The present invention relates to devices and methods for depositingmaterials onto substrates. The present invention relates to devices andmethods for depositing the materials to make devices or to coat devices.The present invention relates to devices and methods for coating medicaldevices including microprojection arrays. The present invention relatesto novel print head designs that utilize a piezoelectric stack actuatoras the driving component to push a membrane plate such that the fluid inthe pumping chamber is dispensed though a two-dimensional array ofnozzles. The dispensed fluid is coated onto microprojections on amicroprojection array as the nozzles are aligned with themicroprojections on the array. The number of nozzle in each of thetwo-dimensional directions may be less than 100 nozzles and the numberof nozzles may be evenly divided by the number of projections in themicroneedle array that is being coated or may be the same number as thenumber of projections to be coated. The spacing between the nozzles maybe a whole number multiple of the spacing between the microprojectionsin the microprojection array. The device and methods of the presentinvention may provide that each drop ejection cycle enable all thenozzles to simultaneously dispense a drop or a sequence of drops with atotal volume in the range of 30 to 3000 picoliters per nozzle. Thedevice and methods of the present invention may provide that each dropejection cycle enable a single nozzle or subset of nozzles to dispense adrop or a sequence of drops.

The devices and methods of the present invention provide a print head inwhich the nozzle plate provides a two-dimensional array of nozzle fordispensing material.

(a) Print Head Device

One embodiment of the print head device of the present invention isshown in FIGS. 1 and 2. In this embodiment of the print head device apiezoelectric stack actuator is used. In FIG. 1, the housing (101) isconnected to the pumping chamber (106) where the fluid to be dispensedis stored. The fluid flows into the pumping chamber through one or moreports (107). The piezoelectric stack (102) is activated and impinges onthe plate membrane (104) which is held between two restrictor plates(103 and 105). The descender plate (108) is attached to the nozzle plate(109) such that when the piezoelectric stack (102) is activated, fluidis pushed by the plate membrane (104) through the descender plate (108)and out through the nozzles in the nozzle plate (109) to be distributedonto the microprojections. In this embodiment the print head isassembled by passing the screws through the housing (101), the firstrestrictor plate (103), the membrane plate (104), the second restrictorplate (105) and into the pumping chamber (106). The pre-loaded force ofthe stack PZT (102) onto the membrane plate (104) is set using a directcurrent force gauge. The pre-loaded force is used to fine tune theperformance of the different print head assemblies so that optimalperformance may be achieved. In this embodiment of the print head thecomponents above the membrane plate (i.e. the housing (101), stack PZT(102) and first restrictor plate (103)) where no fluid contacts theparts can sterilized and re-used. The components below and including themembrane plate may be disposable. The restrictor plates may serve as aninternal fluidic conduit where the biological fluid flows through therestrictor and into the area below the membrane plate.

FIGS. 3-6 provide alternate embodiments of the print head device of thepresent invention in which a unimorph piezoelectric unit is used. InFIG. 3, the housing (301) is connected to the pumping chamber (305)where the fluid to be dispensed is stored. The fluid flows into thepumping chamber through one or more ports (306). The unimorphpiezoelectric device (302) is activated and impinges on the platemembrane (303) which is held by a restrictor plate (304). The descenderplate (307) is attached to the nozzle plate (308) such that when theunimorph piezoelectric (302) is activated, fluid is pushed by the platemembrane (304) through the descender plate (307) and out through thenozzles in the nozzle plate (308) to be distributed onto themicroprojections.

In FIG. 5 an embodiment is shown where the housing (501) has ports (501)for conducting fluid into the pumping chamber (506). The unimorph PZT(503) impacts the plate membrane (504) which is held in place by arestrictor plate (505). All of these parts are assembled with thehousing (506) and the descender plate (507) and nozzle plate (508). Theembodiments utilizing the unimorph PZT are assembled using abio-compatible epoxy. The unimorph PZT is significantly less expensivethan the stack PZT and thus the manufacturing cost may be loweredproviding a print head that is fully disposable. Because the unimorphPZT has less variability in its performance, the product performancevariation may be tighter. Because unimorph PZT is smaller, the printhead footprint may be smaller as well (e.g. 30×30×30 mm). Finally, thecompliance of the unimorph PZT is higher than that of stack PZT and as aresult the jet performance may be better tuned than that of stack PZTversions. FIG. 9 show a schematic diagram of one embodiment of thepiezoelectric stack actuator

FIGS. 10A and B show views of one embodiment of the assembled print headdevice. FIG. 11 provides an additional embodiment of the print head ofthe present invention. The parts of this embodiment of the print headinclude the piezoelectric device (1103), the membrane plate (1104), thedeformation clearance plate (1101), the restrictor pumping chamber(1102) and the nozzle plate (1108). The deformation clearance plate isbetween the membrane plate and the pumping chamber plate. The membraneplate is deformed by the piezoelectric actuator toward the deformationclearance plate and the maximum deformable area in the membrane plate isdefined by the deformation clearance plate. In this example, thedeformation clearance plate (1101) is functioning in a manner similar tothe restrictor plate (105) of the previous examples. Whilst therestrictor pumping chamber (1102) is providing functionality broadlyequivalent to the pumping chamber (106) of the previous examples. Itwill therefore be appreciated that reference to particular terminologyis not necessarily intended to be restrictive, but is merelyillustrative of functionality provided. FIG. 12 provides a schematic ofa top view of one embodiment of the restrictor pumping chamber.

FIG. 13 provides a schematic diagram of the print head assembly shown inFIG. 11 within a housing which includes the cartridge cap (1310), thecartridge body (1311) and an adapter plate (1312). The adapter plate maybe removable which permits the interchange of nozzle arrays. FIGS. 14A-Cand 15A and B show various views of the print head assembly inside thehousing.

The various parts of the print head may be assembled in a variety ofways including but not limited to diffusion bonding, epoxy bonding,laser welding or a combination thereof. In diffusion bonding the partsof the print head assembly are coated with a bonding layer (e.g. gold),aligned and then diffusion bonded. Diffusion bonding may be preferred asit is a more permanent approach less prone to leakage and hole blockagedue to adhesive leaking into the holes. In epoxy boding a thin layer ofadhesive (approximately 3 μm) is applied to each surface and the partsare aligned in a jig and then placed under pressure and heat to bond. Inlaser welding the areas that require a water tight bond are laser weldedin order to build the final assembly. For example, with respect to FIG.11, the piezoelectric device (1103) may be adhesive bonded to themembrane plate (1104) to form one sub-assembly. The deformationclearance plate (1101), the restrictor pumping chamber (1102) and thenozzle plate (1108) can be diffusion bonded to one another to form asecond sub-assembly. These two sub-assemblies can then be adhesivebonded together to form the print head. Alternatively the deformationclearance plate (1101), the restrictor pumping chamber (1102) and thenozzle plate (1108) can be laser welded together and this sub-assemblyadhesive bonded to the piezoelectric device (1103)/membrane plate (1104)sub-assembly. Another alternative is to adhesive bond all of the partstogether.

In one embodiment of the print head of the present invention the printhead functions in the following way. The print head has a source offluid from a reservoir which may be integral or externally located.Initially, the fluid from the reservoir to the nozzle is at a staticcondition, i.e., no flow. Between the reservoir and the nozzle, thereare microfluidic conduits and a pumping chamber. The microfluidicconduits are responsible for replenishing fluid from the reservoir tothe pumping chamber. The pumping chamber is responsible for pumpingfluid out from the nozzle. At the nozzle exit, there is a meniscus orliquid/air interface defined by the nozzle exit geometry, which is someembodiments forms a round meniscus. At the static condition, themeniscus has a concave shape, which generates a capillary pressure andprovides the means to maintain the fluid inside the pumping chamber fromleaking out from the nozzle. At certain time t=0, the piezoelectricactuator is energized by the electric driving signal. At t=t1, theactivation of the piezoelectric actuator is complete. The activatedpiezoelectric actuator then pushes the membrane plate to generate apositive pressure wave in the pumping chamber. The fluid inside thepumping chamber propagates the pressure wave in all directions, i.e.,through the nozzle to the nozzle meniscus and through the fluidicconduits to the reservoir. The pressure wave that is propagated to thereservoir is dampened out as the reservoir has a huge free surface (alarge liquid/air interface with lots of compliance). The pressure waveis propagated to the nozzle exit at t=t2 and if the wave pressureexceeds the capillary pressure, the fluid will deform the nozzlemeniscus changing the meniscus from a concave shape to a convex shape.If the pressure wave is much greater than the capillary pressure of thenozzle meniscus, the wave will continue pushing fluid through the nozzleand push the convex meniscus into a liquid ligament. The liquid ligamentbreaks at the nozzle exit at t=t3 largely due to Rayleigh instabilityinduced by the pressure wave itself. This action forms a drop or dropsat a speed typically greater than 1 m/s toward the substrate. After theligament is broken at the nozzle exit, the residual fluid will oscillateand return to form a concave nozzle meniscus. In above mentioned dropformation process, due to the law of mass conservation, the fluid insidethe reservoir must replenish the fluid conduits, the pumping chamber,and the nozzle hole with the amount equal to the drop(s) volume. Thereplenishment process involves a creeping flow phenomenon, i.e., thefluid slowly creeps into the space between the reservoir and the nozzlemeniscus. This phenomenon is complete at t=t4. The residual pressurewave may still be oscillating inside the pumping chamber but because theamplitude is less than the capillary pressure, no additional drop(s)will be generated. At t=t5, the residual pressure wave eventuallydampens out. The entire system returns to a static state condition inpreparation for the next electrical signal to activate the piezoelectricactuator. This describes one printhead drop formation cycle. The reverseof this cycle defines the jetting frequency. Typically, tl is less thana few microseconds; t2−t1 is less than a few microseconds; t3−t2 is lessthan tens of microsecond; t4 is about the same as t3; t5 may be abouthundreds of seconds.”

In embodiments of the print head that have a descender plate and anozzle plate the alignment of the descender plate and nozzle plate is animportant factor in the performance of the print head. An alignment toolmay be used to align these two plate such that the holes in each thedescender plate and nozzle plate are aligned with each other.

In some alternative embodiments, the print head may be constructedwithout a deformation clearance plate or its functional equivalents asdiscussed above. Whilst the deformation clearance plate may be used toretain in place a portion of the membrane that is not used in pushingthe fluid, it will be appreciated that a similar outcome may be achievedusing other techniques that do not necessarily require a separatedeformation clearance plate, such as by way of a thickened membrane orpumping chamber plate. In some examples, the functionality described forthe deformation clearance plate may be provided by alternativestructural arrangements that do necessarily involve the use of a plate.

Accordingly, another form of the print head device may be broadlydefined as comprising a restrictor pumping chamber containing a fluid, anozzle arrangement including a plurality of nozzles in fluidcommunication with the restrictor pumping chamber, a piezoelectricactuator, and a membrane provided adjacent the piezoelectric actuatorand spaced apart from the restrictor pumping chamber such thatactivation of the piezoelectric actuator urges the membrane into contactwith fluid in the restrictor pumping chamber to thereby urge fluid intothe nozzles and thereby eject coating solution onto the substrate.

(b) Nozzles

The number of nozzle in each of the two-dimensional directions may beless than 100 nozzles or less than 90 nozzles or less than 80 nozzles orless than 70 nozzles or less than 60 nozzles or less than 50 nozzles orless than 40 nozzles or less than 30 nozzles or less than 20 nozzles orless than 10 nozzles. The number of nozzles in a given direction may bebetween 10 and 100 nozzles or between 10 and 90 nozzles or between 10and 80 nozzles or between 10 and 70 nozzles or between 10 and 60 nozzlesor between 10 and 50 nozzles or between 10 and 40 nozzles or between 10and 30 nozzles or between 10 and 20 nozzles or be between 20 and 100nozzles or between 20 and 90 nozzles or between 20 and 80 nozzles orbetween 20 and 70 nozzles or between 20 and 60 nozzles or between 20 and50 nozzles or between 20 and 40 nozzles or between 20 and 30 nozzles orbe between 30 and 100 nozzles or between 30 and 90 nozzles or between 30and 80 nozzles or between 30 and 70 nozzles or between 30 and 60 nozzlesor between 30 and 50 nozzles or between 30 and 40 nozzles or be between40 and 100 nozzles or between 40 and 90 nozzles or between 40 and 80nozzles or between 40 and 70 nozzles or between 40 and 60 nozzles orbetween 40 and 50 nozzles or be between 50 and 100 nozzles or between 50and 90 nozzles or between 50 and 80 nozzles or between 50 and 70 nozzlesor between 50 and 60 nozzles.

Nozzles can be spaced between about 50 to 500 micrometers, or from about50 to 450 micrometers or from about 50 to 400 micrometers, or from about50 to 350 micrometers or from about 50 to 300 micrometers, or from about50 to 250 micrometers or from about 50 to 200 micrometers, or from about50 to 150 micrometers or from about 50 to 100 micrometers, or from about100 to 500 micrometers or from about 100 to 450 micrometers, or fromabout 100 to 400 micrometers or from about 100 to 350 micrometers orfrom about 100 to 300 micrometers, or from about 100 to 250 micrometersor from about 100 to 500 micrometers or from about 100 to 450micrometers, or from about 100 to 400 micrometers or from about 100 to350 micrometers or from about 100 to 300 micrometers, or from about 100to 250 micrometers or from about 100 to 200 micrometers or from about100 to 150 micrometers, or from about 150 to 500 micrometers or fromabout 150 to 450 micrometers or from about 150 to 400 micrometers orfrom about 150 to 350 micrometers or from about 150 to 300 micrometersor from about 150 to 250 micrometers, or from about 150 to 200micrometers or from about 200 to 500 micrometers or from about 200 to450 micrometers, or from about 200 to 400 micrometers or from about 200to 350 micrometers or from about 200 to 300 micrometers, or from about200 to 250 micrometers or from about 250 to 500 micrometers or fromabout 250 to 450 micrometers, or from about 250 to 400 micrometers orfrom about 250 to 350 micrometers or from about 250 to 300 micrometers,or from about 300 to 500 micrometers or from about 300 to 450micrometers or from about 300 to 400 micrometers, or from about 300 to350 micrometers or from about 350 to 500 micrometers or from about 350to 450 micrometers, or from about 350 to 400 micrometers or from about400 to 500 micrometers or from about 400 to 450 micrometers.

The density of the nozzles in the nozzle array may be from about 1,000to 10,000 nozzles per cm², or from about 1,000 to 9,000 nozzles per cm²or from 1000 to 8,500 nozzles per cm², or from about 1000 to 8,000nozzles per cm² or from 1,000 to 7,500 nozzles per cm², or from about1,000 to 7,000 nozzles per cm² or from about 1,000 to 6,500 nozzles percm², or from about 1,000 to 6,000 nozzles per cm² or from 1,000 to 5,500nozzles per cm², or from about 1,000 to 5,000 nozzles per cm² or from1,000 to 4,500 nozzles per cm², or from about 1,000 to 4,000 nozzles percm², about 1,000 to 3,500 nozzles per cm², or from about 1,000 to 3,000nozzles per cm² or from 1,000 to 2,500 nozzles per cm², or from about1,000 to 2,000 nozzles per cm², or from about 1,000 to about 1,500nozzles per cm², or from about 1,500 to 10,000 nozzles per cm², or fromabout 1,500 to 9,000 nozzles per cm² or from 1,500 to 8,500 nozzles percm², or from about 1000 to 8,000 nozzles per cm² or from 1,500 to 7,500nozzles per cm², or from about 1,500 to 7,000 nozzles per cm² or fromabout 1,500 to 6,500 nozzles per cm², or from about 1,500 to 6,000nozzles per cm² or from 1,500 to 5,500 nozzles per cm², or from about1,500 to 5,000 nozzles per cm² or from 1,500 to 4,500 nozzles per cm²,or from about 1,500 to 4,000 nozzles per cm², about 1,500 to 3,500nozzles per cm², or from about 1,500 to 3,000 nozzles per cm² or from1,500 to 2,500 nozzles per cm², or from about 1,500 to 2,000 nozzles percm², or from about 2,000 to 10,000 nozzles per cm², or from about 2,000to 9,000 nozzles per cm² or from 2,000 to 8,500 nozzles per cm², or fromabout 1000 to 8,000 nozzles per cm² or from 2,000 to 7,500 nozzles percm², or from about 2,000 to 7,000 nozzles per cm² or from about 2,000 to6,500 nozzles per cm², or from about 2,000 to 6,000 nozzles per cm² orfrom 2,000 to 5,500 nozzles per cm², or from about 2,000 to 5,000nozzles per cm² or from 2,000 to 4,500 nozzles per cm², or from about2,000 to 4,000 nozzles per cm², about 2,000 to 3,500 nozzles per cm², orfrom about 2,000 to 3,000 nozzles per cm² or from 2,000 to 2,500 nozzlesper cm², or from about 2,500 to 10,000 nozzles per cm², or from about2,500 to 9,000 nozzles per cm² or from 2,500 to 8,500 nozzles per cm²,or from about 1000 to 8,000 nozzles per cm² or from 2,500 to 7,500nozzles per cm², or from about 2,500 to 7,000 nozzles per cm² or fromabout 2,500 to 6,500 nozzles per cm², or from about 2,500 to 6,000nozzles per cm² or from 2,500 to 5,500 nozzles per cm², or from about2,500 to 5,000 nozzles per cm² or from 2,500 to 4,500 nozzles per cm²,or from about 2,500 to 4,000 nozzles per cm², about 2,500 to 3,500nozzles per cm², or from about 2,500 to 3,000 nozzles per cm² or fromabout 3,000 to 10,000 nozzles per cm², or from about 3,000 to 9,000nozzles per cm² or from 1000 to 8,500 nozzles per cm², or from about3,000 to 8,000 nozzles per cm² or from 3,000 to 7,500 nozzles per cm²,or from about 3,000 to 7,000 nozzles per cm² or from about 3,000 to6,500 nozzles per cm², or from about 3,000 to 6,000 nozzles per cm² orfrom 3,000 to 5,500 nozzles per cm², or from about 3,000 to 5,000nozzles per cm² or from 3,000 to 4,500 nozzles per cm², or from about3,000 to 4,000 nozzles per cm², about 3,000 to 3,500 nozzles per cm², orfrom about 3,500 to 10,000 nozzles per cm², or from about 3,500 to 9,000nozzles per cm² or from 3,500 to 8,500 nozzles per cm², or from about3,500 to 8,000 nozzles per cm² or from 3,500 to 7,500 nozzles per cm²,or from about 3,500 to 7,000 nozzles per cm² or from about 3,500 to6,500 nozzles per cm², or from about 3,500 to 6,000 nozzles per cm² orfrom 3,500 to 5,500 nozzles per cm², or from about 3,500 to 5,000nozzles per cm² or from 3,500 to 4,500 nozzles per cm², or from about4,000 to 10,000 nozzles per cm², or from about 4,000 to 9,000 nozzlesper cm² or from 4,000 to 8,500 nozzles per cm², or from about 4,000 to8,000 nozzles per cm² or from 4,000 to 7,500 nozzles per cm², or fromabout 4,000 to 7,000 nozzles per cm² or from about 4,000 to 6,500nozzles per cm², or from about 4,000 to 6,000 nozzles per cm² or from4,000 to 5,500 nozzles per cm², or from about 4,000 to 5,000 nozzles percm² or from 4,000 to 4,500 nozzles per cm², or from about 4,500 to10,000 nozzles per cm², or from about 4,500 to 9,000 nozzles per cm² orfrom 4,500 to 8,500 nozzles per cm², or from about 4,500 to 8,000nozzles per cm² or from 4,500 to 7,500 nozzles per cm², or from about4,500 to 7,000 nozzles per cm² or from about 4,500 to 6,500 nozzles percm², or from about 4,500 to 6,000 nozzles per cm² or from 4,500 to 5,500nozzles per cm², or from about 4,500 to 5,000 nozzles per cm² or fromabout 5000 to 10,000 nozzles per cm², or from about 5,000 to 9,000nozzles per cm² or from 5,000 to 8,500 nozzles per cm², or from about5,000 to 8,000 nozzles per cm² or from 5,000 to 7,500 nozzles per cm²,or from about 5,000 to 7,000 nozzles per cm² or from about 5,000 to6,500 nozzles per cm², or from about 5,000 to 6,000 nozzles per cm² orfrom 5,000 to 5,500 nozzles per cm², or from about 5,500 to 10,000nozzles per cm², or from about 5,500 to 9,000 nozzles per cm² or from5,500 to 8,500 nozzles per cm², or from about 5,500 to 8,000 nozzles percm² or from 5,500 to 7,500 nozzles per cm², or from about 5,500 to 7,000nozzles per cm² or from about 5,500 to 6,500 nozzles per cm², or fromabout 5,500 to 6,000 nozzles per cm².

In the simplest scenario the number of nozzles would correspond directlyto the number of projections on the microprojection array. For exampleif the two dimensional nozzle array had 38×38 nozzles (1444 totalnozzles) the microprojection array would have 1444 projections in thesame spatial orientation as the nozzle array for a one-to onecorrespondence. In this case the spacing of the microprojections on themicroprojection array would be the same as the spacing of the nozzles.In some cases the spacing of the microprojections may be closer thanthat of the nozzles. For example if the spacing between microprojectionson a microprojection array is 120 micrometers, the spacing of thenozzles may be 240 micrometers such that the nozzles would coat everyother microprojection. In such a case the correspondence of the nozzlesto the microprojections would be 1 to 2. For example if the spacingbetween microprojections on a microprojection array is 120 micrometers,the spacing of the nozzles may be 480 micrometers such that the nozzleswould coat every fourth microprojection. In such a case thecorrespondence of the nozzles to the microprojections would be 1 to 4.

By making the pitch of the nozzles equal the pitch of the projections,and producing the same 2D array in the nozzles as to match theprojection array the design is not limited to uniform square orrectangular arrays but can print abstract geometric shapes, (smileyface, circular etc.) Not having to move the print head over the arrayspeeds up the process and improves targeting accuracy.

In some embodiments of the device and methods of the present inventionthe nozzle array of the print head will not coat all of themicroprojections designated for coating in a single pass. For example ifthe nozzle array is two dimensional array that has 38×38 nozzles and themicroprojection array has 5776 microprojections arranged as a 76×76array the nozzles may need to move relative to the microprojectionarray. In such a scenario the microprojection array can be seen ashaving four quadrants each of 1444 microprojections. To coat theprojections on the entire array the print head carrying the nozzles canbe moved relative to the microprojection array three times after thefirst positioning such that each of the quadrants can be coated.Alternatively the microprojection array can be moved relative to theprint head and again the four quadrants can be coated. In like mannerany microprojection array that has a number of microprojections that area multiple of the number of nozzles can be coated by the print head bymoving the print head or microprojection array relative to each othersuch that the nozzles are aligned over the microprojection quadrant byquadrant. It may also be possible as described above that themicroprojections of the microprojection array are more closely spacedthan the nozzles of the print head. For example the microprojectionarray may have 11552 and the nozzle array has 38×38 nozzles which arealigned with every other microprojection. The nozzle array may coatevery other microprojection in the first or four quadrants and then themicroprojection array and the nozzle array can be moved relative to eachother such that a second microprojection array quadrant can be coatedand so on so that the entire microprojection array is coated havingevery other microprojection coated.

The nozzles can be arrayed in a nozzle plate as shown in FIGS. 16A-D.The two-dimensional array of nozzles can be made from but is not limitedto materials such as etched silicon or electroformed nickel. The nozzleplate may be attached to a descender plate (FIG. 16D) which is attachedto a pumping chamber (FIG. 7) such that the combination of the nozzleplate/descender plate and the pumping chamber are sealed and permit theinflux of a fluid to be dispensed through the nozzles in the nozzleplate. The descender plate and nozzle plate may be attached by directbonding if silicon is used or if stainless steel plates are used theneither epoxy bonding or diffusion bonding can be used. Alternativelythere may be a single nozzle plate without a descender plate. If thereis only one plate below the pumping chamber plate, it is called nozzleplate. If however two plates are used to make the nozzle plate, then thetop one is called descender plate and the bottom one is called thenozzle plate.

In one embodiment the nozzle plate and descender plate are 20×20 mmsquare. In one embodiment the nozzle plate the thickness of nozzle plateis 0.05 to 0.1 mm and the thickness of descender plate is 0.10 0.25 to1.0 mm. The nozzle plate may be coated to enhance durability andhydrophobicity. The nozzle plate may also have fluidic ports which aremoulded or machined into the plate permit filling of the pumping chamberand recirculation of the fluid during the coating process. (FIG. 8) Therecirculation of the fluid during the coating process may provide mixingfor the fluid.

The drop size may be determined by the energy of the drop mass. If thedrop is too large it will not remain at the top of the projection butslide down the projection towards the base. If the drop is too large itmay also span more than one projection. If the drop is too small theprocess becomes inefficient. Stability data indicates that smallerquicker drying drops may provide longer shelf life. Drop size may beless than 500 pl or less than 400 pl or less than 300 pl or less than200 pl or less than 100 pl. Drop size may range from about 10 pl toabout 500 pl or from about 10 pl to about 400 pl or from about 10 pl toabout 300 pl or from about 10 pl to about 200 pl or from about 10 pl toabout 100 pl or from about 10 pl to about 50 pl or from about 50 pl toabout 500 pl or from about 50 pl to about 400 pl or from about 50 pl toabout 300 pl or from about 50 pl to about 200 pl or from about 50 pl toabout 100 pl or from about 100 pl to about 500 pl or from about 100 plto about 400 pl or from about 100 pl to about 300 pl or from about 100pl to about 200 pl or from about 200 pl to about 500 pl or from about200 pl to about 400 pl or from about 200 pl to about 300 pl. Drop sizemay be about 100 pl or 105 pl or 110 pl or 115 pl or 120 pl or 125 pl or130 pl or 135 pl or 140 pl or 145 pl or 150 pl.

Each drop ejection cycle enables all the nozzles to simultaneouslydispense a drop or a sequence of drops with a total volume in the rangeof 20 to 3000 picoliters, or 20 to 2500 picoliters, or 20 to 2000picoliters or 20 to 1500 picoliters or 20 to 1000 picoliters, or 20 to900 picoliters, or 20 to 800 picoliters, or 20 to 700 picoliters, or 20to 600 picoliters, or 20 to 500 picoliters, or 20 to 400 picoliters, or20 to 300 picoliters, or 20 to 200 picoliters, or 20 to 100 picoliters,or 20 to 90 picoliters, or 20 to 80 picoliters or 20 to 70 picoliters,or 20 to 60 picoliters, or 20 to 50 picoliters, or 20 to 40 picolitersor 20 to 30 picoliters, or 30 to 3000 picoliters, or 30 to 2500picoliters, or 30 to 2000 picoliters or 30 to 1500 picoliters or 30 to1000 picoliters, or 30 to 900 picoliters, or 30 to 800 picoliters, or 30to 700 picoliters, or 30 to 600 picoliters, or 30 to 500 picoliters, or30 to 400 picoliters, or 30 to 300 picoliters, or 30 to 200 picoliters,or 30 to 100 picoliters, or 30 to 90 picoliters, or 30 to 80 picolitersor 30 to 70 picoliters, or 30 to 60 picoliters, or 30 to 50 picoliters,or 30 to 40 picoliters or 40 to 3000 picoliters, or 40 to 2500picoliters, or 40 to 2000 picoliters or 40 to 1500 picoliters or 40 to1000 picoliters, or 40 to 900 picoliters, or 40 to 800 picoliters, or 40to 700 picoliters, or 40 to 600 picoliters, or 40 to 500 picoliters, or40 to 400 picoliters, or 40 to 300 picoliters, or 40 to 200 picoliters,or 40 to 100 picoliters, or 40 to 90 picoliters, or 40 to 80 picolitersor 40 to 70 picoliters, or 40 to 60 picoliters, or 40 to 50 picoliters,50 to 3000 picoliters, or 50 to 2500 picoliters, or 50 to 2000picoliters or 50 to 1500 picoliters or 50 to 1000 picoliters, or 50 to900 picoliters, or 50 to 800 picoliters, or 50 to 700 picoliters, or 50to 600 picoliters, or 50 to 500 picoliters, or 50 to 400 picoliters, or50 to 300 picoliters, or 50 to 200 picoliters, or 50 to 100 picoliters,or 50 to 90 picoliters, or 50 to 80 picoliters or 50 to 70 picoliters,or 50 to 60 picoliters, or 60 to 3000 picoliters, or 60 to 2500picoliters, or 60 to 2000 picoliters or 60 to 1500 picoliters or 60 to1000 picoliters, or 60 to 900 picoliters, or 60 to 800 picoliters, or 60to 700 picoliters, or 60 to 600 picoliters, or 60 to 500 picoliters, or60 to 400 picoliters, or 60 to 300 picoliters, or 60 to 200 picoliters,or 60 to 100 picoliters, or 60 to 90 picoliters, or 60 to 80 picolitersor 60 to 70 picoliters, or 70 to 3000 picoliters, or 70 to 2500picoliters, or 70 to 2000 picoliters or 70 to 1500 picoliters or 70 to1000 picoliters, or 70 to 900 picoliters, or 70 to 800 picoliters, or 70to 700 picoliters, or 70 to 600 picoliters, or 70 to 500 picoliters, or70 to 400 picoliters, or 70 to 300 picoliters, or 70 to 200 picoliters,or 70 to 100 picoliters, or 70 to 90 picoliters, or 70 to 80 picolitersor 80 to 3000 picoliters, or 80 to 2500 picoliters, or 80 to 2000picoliters or 80 to 1500 picoliters or 80 to 1000 picoliters, or 80 to900 picoliters, or 80 to 800 picoliters, or 80 to 700 picoliters, or 80to 600 picoliters, or 80 to 500 picoliters, or 80 to 400 picoliters, or80 to 300 picoliters, or 80 to 200 picoliters, or 80 to 100 picoliters,or 80 to 90 picoliters, or 90 to 3000 picoliters, or 90 to 2500picoliters, or 90 to 2000 picoliters or 90 to 1500 picoliters or 90 to1000 picoliters, or 90 to 900 picoliters, or 90 to 800 picoliters, or 90to 700 picoliters, or 90 to 600 picoliters, or 90 to 500 picoliters, or90 to 400 picoliters, or 90 to 300 picoliters, or 90 to 200 picoliters,or 90 to 100 picoliters, or 100 to 1000 picoliters, or 100 to 900picoliters, or 100 to 800 picoliters, or 100 to 700 picoliters, or 100to 600 picoliters, or 100 to 500 picoliters, or 100 to 400 picoliters,or 100 to 300 picoliters, or 100 to 200 picoliters, or 200 to 1000picoliters, or 200 to 900 picoliters, or 200 to 800 picoliters, or 200to 700 picoliters, or 200 to 600 picoliters, or 200 to 500 picoliters,or 200 to 400 picoliters, or 200 to 300 picoliters, or 300 to 1000picoliters, or 300 to 900 picoliters, or 300 to 800 picoliters, or 300to 700 picoliters, or 300 to 600 picoliters, or 300 to 500 picoliters,or 300 to 400 picoliters, or 400 to 1000 picoliters, or 400 to 900picoliters, or 400 to 800 picoliters, or 400 to 700 picoliters, or 400to 600 picoliters, or 400 to 500 picoliters, or 500 to 1000 picoliters,or 500 to 900 picoliters, or 500 to 800 picoliters, or 500 to 700picoliters, or 500 to 600 picoliters, or 600 to 1000 picoliters, or 600to 900 picoliters, or 600 to 800 picoliters, or 600 to 700 picoliters,or 700 to 1000 picoliters, or 700 to 900 picoliters, or 700 to 800picoliters or 800 to 1000 picoliters, or 800 to 900 picoliters, or 900to 1000 picoliters. The drop size of each individual drop may be fromabout 100 to 200 picoliters, or 100 to 190 picoliters, or 100 to 180picoliters, or 100 to 170 picoliters, or 100 to 160 picoliters, or 100to 150 picoliters, or 100 to 140 picoliters, or 100 to 130 picoliters,or 100 to 120 picoliters or from 100 to 110 picoliters, or from about110 to 200 picoliters, or 110 to 190 picoliters, or 110 to 180picoliters, or 110 to 170 picoliters, or 110 to 160 picoliters, or 110to 150 picoliters, or 110 to 140 picoliters, or 110 to 130 picoliters,or 110 to 120 picoliters or from about 120 to 200 picoliters, or 120 to190 picoliters, or 120 to 180 picoliters, or 120 to 170 picoliters, or120 to 160 picoliters, or 120 to 150 picoliters, or 120 to 140picoliters, or 120 to 130 picoliters, or from about 130 to 200picoliters, or 130 to 190 picoliters, or 130 to 180 picoliters, or 130to 170 picoliters, or 130 to 160 picoliters, or 130 to 150 picoliters,or 130 to 140 picoliters, or from about 140 to 200 picoliters, or 140 to190 picoliters, or 140 to 180 picoliters, or 140 to 170 picoliters, or140 to 160 picoliters, or 140 to 150 picoliters, or from about 150 to200 picoliters, or 150 to 190 picoliters, or 150 to 180 picoliters, or150 to 170 picoliters, or 150 to 160 picoliters, or from about 160 to200 picoliters, or 160 to 190 picoliters, or 160 to 180 picoliters, or160 to 170 picoliters, or 170 to 200 picoliters, or 170 to 190picoliters, or 170 to 180 picoliters, or 180 to 200 picoliters, or 180to 190 picoliters or from 190 to 200 picoliters.

The frequency of dispensing the drops is from about 1 Hz to about 1000Hz or from about 1 Hz to about 900 Hz or from about 1 Hz to about 800 Hzor from about 1 Hz to about 700 Hz or from about 1 Hz to about 600 Hz orfrom about 1 Hz to about 500 Hz or from about 1 Hz to about 400 Hz orfrom about 1 Hz to about 300 Hz or from about 1 Hz to about 200 Hz orfrom about 1 Hz to about 100 Hz or from about 1 Hz to about 90 Hz orfrom about 1 Hz to about 80 Hz or from about 1 Hz to about 70 Hz or fromabout 1 Hz to about 60 Hz or from about 1 Hz to about 50 Hz or fromabout 1 Hz to about 40 Hz or from about 1 Hz to about 30 Hz or fromabout 1 Hz to about 20 Hz or from about 1 Hz to about 10 Hz or fromabout 10 Hz to about 100 Hz or from about 10 Hz to about 90 Hz or fromabout 10 Hz to about 80 Hz or from about 10 Hz to about 70 Hz or fromabout 10 Hz to about 60 Hz or from about 10 Hz to about 50 Hz or fromabout 10 Hz to about 40 Hz or from about 10 Hz to about 30 Hz or fromabout 10 Hz to about 20 Hz or from about 20 Hz to about 100 Hz or fromabout 20 Hz to about 90 Hz or from about 20 Hz to about 80 Hz or fromabout 20 Hz to about 70 Hz or from about 20 Hz to about 60 Hz or fromabout 20 Hz to about 50 Hz or from about 20 Hz to about 40 Hz or fromabout 20 Hz to about 30 Hz or from about 30 Hz to about 100 Hz or fromabout 30 Hz to about 90 Hz or from about 30 Hz to about 80 Hz or fromabout 30 Hz to about 70 Hz or from about 30 Hz to about 60 Hz or fromabout 30 Hz to about 50 Hz or from about 30 Hz to about 40 Hz or fromabout 40 Hz to about 100 Hz or from about 40 Hz to about 90 Hz or fromabout 40 Hz to about 80 Hz or from about 40 Hz to about 70 Hz or fromabout 40 Hz to about 60 Hz or from about 40 Hz to about 50 Hz or fromabout 50 Hz to about 100 Hz or from about 50 Hz to about 90 Hz or fromabout 50 Hz to about 80 Hz or from about 50 Hz to about 70 Hz or fromabout 50 Hz to about 60 Hz or from about 60 Hz to about 100 Hz or fromabout 60 Hz to about 90 Hz or from about 60 Hz to about 80 Hz or fromabout 60 Hz to about 70 Hz or from about 70 Hz to about 100 Hz or fromabout 70 Hz to about 90 Hz or from about 70 Hz to about 80 Hz or fromabout 80 Hz to about 100 Hz or from about 80 Hz to about 90 Hz or fromabout 90 Hz to about 100 Hz.

In some cases a burst mode priming procedure may be run at highfrequencies, for example about 1 kHz for 10 bursts. At higher frequency,such a priming mode may be used to re-establish the meniscus positionand shape.

FIG. 17 shows an embodiment of the print heads of the present inventionin which the top plate is less than 100 μm and has one inlet and oneoutlet which can provide for the recirculation of fluid. The print headhas a top plate (1711) which has a single inlet (1712) and outlet(1713). Below the top plate (1711) is a fluid distribution plate (1714)which has reservoirs (1715) for the printing fluid. Below the fluiddistribution plate is the piezoelectric device (1716) below which is thepiezoelectric membrane (1717), both of which are within thepiezoelectric-membrane plate (1718). Below the piezoelectric-membraneplate (1718) is the piezoelectric deformation clearance plate (1719) andbelow that is the pumping chamber plate (1720). Below the pumpingchamber plate (1720) is the nozzle plate (1721) Both the inlet and theoutlet can be used to fill the print head with fluid. The distributionplate may be up to 2 mm thick and provides two reservoirs to help dampenthe acoustic wave transmitted from the pumping chamber through therestrictors. The larger the volume of the reservoirs the better thedampening and frequency response which will maintain drop size and dropvelocity. The centre ring of the plate should be at least 1mm larger indiameter than the diameter of the piezo. This is used to clamp thePZT-membrane plate to have a simply supported beam structure so thatdeformation of the PZT can still be achieved. The PZT plate providesacoustic energy for drop formation. The PZT is actuated by electricsignals which pushes the membrane which in turn creates a pressurechange in the fluid below the membrane. The membrane plate in preferredembodiments of the print heads of the present invention is about or lessthan 100 μm in thickness. The PZT deformation clearance plate should befrom about 20 to 60 μm in thickness.

FIG. 18A and 18B discloses a preferred embodiment of the pumping chamberplate of the print heads of the present invention. FIG. 18A is a topview of the pumping chamber plate and 18B is a top view of the assembly.The fluid comes in from the fluid inlet (1801), then flows into thepumping chamber area through a restrictor 1 (1802). After the pumpingchamber is filled with fluid the fluid flows through restrictor 2 (1803)to the fluid outlet (1804). The dimensions of the pumping chamber shouldbe slightly larger than the nozzle array dimensions. As can be seen inFIG. 18B there are several air venting facilities (1805) which surroundthe pumping chamber such that as the chamber is filled the air in eacharea of the pumping chamber has a separate channel to escape. Thefluidic path has a rounded contour to reduce pressure shock to thepumping chamber and to maintain a low Reynolds number flow during theprocess of filling the pumping chamber. The sharpened edge shown in FIG.18C creates a pinning point for the moving contact line to retard thespeed of the edge of the moving contact line.

Unlike conventional nozzle plates where all of the openings are used fordrop formation the nozzle plates of the present invention may provideventing holes (usually less than 50 μm in diameter) that are connectedto each air venting facility in the pumping chamber plate. (FIG. 19A and19B). In a preferred embodiment, these venting holes are straight holeswithout tapering such that they create high flow resistance to stop dropformation during PZT actuation. The diameter of the vent holes should besmaller than the nozzle hole diameter to prevent leaking. FIGS. 20A-Cshow sequential view of the filling of the chamber.

The pumping chamber can be manufactured from a single solid moulded bodyof boro-silicate or quartz glass. In this way, a minimum number of partscan used thereby reducing manufacturing cost and complexity. A membraneplate is disposed in the pumping chamber and may be made of but notlimited to stainless steel, silicon oxide and polyimide (Kapton). Apiezoelectric stack actuator is releasably engaged with the membraneplate such that when electrically actuated the stack pushes the membraneagainst a fluid in the pumping chamber such that the nozzles in thenozzle plate dispense a two dimensional array of drops onto themicroprojections of the microprojection array. The entire device may beenclosed by a housing attached to the pumping chamber. A cooling devicemay be built into the housing of the piezoelectric actuator to reducethe temperature of the fluid to as low at 4° C. In an alternateembodiment the cooling unit may be outside the pumping chamber.

In addition to maintaining temperature control of the fluid to bedispensed, it is desirable to keep the fluid homogeneous by mixing. Themixing of the fluid may be accomplished by mechanisms including but notlimited to a magnetic stirrer or peristaltic pump or micro fluidicchannels driven by a separate PZT or a combination thereof

It is desirable that the output from the high-speed printing of abiological or therapeutic material be monitored such that the amount ofmaterial dispensed can determined so as to ensure the quality of anyproduct made or coated using the high speed printing device. The abilityto monitor the output of the high speed printing device in real timewould provide cost and time saving benefits. One method for monitoringthe output from the nozzles is to weigh the material dispensed. Anothermethod would measure the resistance of a number of dispenses such thatthe amount delivered would fall within a pre-set dispensingparameter(s). While measurement of a single pulse of the piezo unitcorresponding to a single drop is desirable it may be necessary tomeasure a number of dispenses and average the result to determinewhether the amount of material dispensed is accurate. In someembodiments the number of dispenses measured would be from 2 to 10, orfrom 2 to 9, or 2 to 8, or 2 to 7, or 2 to 6 or 2 to 5, or 2 to 4 or 2to 3. In some embodiments the number of dispenses measured would be 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 15 or 20.

It is desirable to be able to monitor the characteristic of the fluid tobe dispensed from the high speed printing device. For example,monitoring the dose, heterogeneity, pH, protein content, viscosity ortemperature of the fluid at any point in time would ensure the qualityof the material to be dispensed.

(c) Drop Mass Dispense Check

Verification of the dispensed dose of a pharmaceutical product is auseful determination in any coating process. It is desirable to be ableto characterize print head performance to ensure the quality of anyproduct made or coated using the high speed printing device. Twopredictors of print performance are drop uniformity and drop velocity.In the print heads of the present invention periodic checks can be madeto measure the mass dispensed from the print head and monitored toensure the amount dispensed is within the accepted tolerance. The printheads of the present invention provide challenges because there is onlya small amount of fluid dispensed per actuation of the nozzle array(e.g. 1,600 nozzles firing about 150 pL drops each=˜240 nL=˜0.24 mg).Coupled with the relatively high rate of evaporation from such smalldrops (due to the surface area) measuring the mass reliably isdifficult. The small drop volume and evaporation issues can be overcomeby two approaches (as well as the combination of the approaches) byincreasing the mass being measured and reducing the effects ofevaporation.

One embodiment is to dispense more drops in rapid succession onto thesame substrate (e.g., different dispense profile from normal patchcoating) which increases the drying rate between subsequent drops.Dispensing multiple drops in rapid succession results in drop merging,which reduces the surface area to volume ratio, and also increases themass. The number of drops to measure can be chosen such that the mass iswell within a range that can be accurately measured in the productionenvironment which for example may be 18-24° C. in a laminar down flowisolator, and would ideally match the number of drops that are intendedto be printed on each patch. As an example, to coat 80 μg HA ofquadrivalent influenza, it would require roughly 21.6 μL of a 3.7 mg/mLstock formulation. The total liquid dispensed would have a mass ofroughly 21.6 mg. The volume might also be chosen to be larger than asingle patch will receive, but still representative of an averagedispensing cycle. A range of 10 to 200 mg may cover the amount ofmaterial to be measured.

A second embodiment is to further minimize evaporation by introducing acheck weigh vessel into the process which might contain a number ofattributes aimed at minimizing evaporation including but not limited tousing: a) a small vessel having walls (or a surface with a recess); b) alid; c) a vessel with a recessed interior; d) a vessel where theinterface of the liquid surface and the air is brought very close to thenozzle ejection plate to minimize the probability that drops will not be“caught” by the liquid (referred to as “the catch liquid”). The catchliquid in the check weigh vessel could be chosen so as to further reducethe evaporation rate of the dispensed material. As such, the catchliquid can be but is not limited to a liquid: a) which is less densethan the dispensed liquid (so that it will naturally be on the surfaceat the liquid-air interface; b) which has a low vapour pressure in theproduction environment conditions (temperature and pressure)-to minimizeevaporative losses; c) which has a low surface tension and viscosity (tofacilitate drop penetration into the liquid); and d) which has anappropriate level of miscibility with the dispensed liquid such that thedispensed liquid is rapidly trapped under a layer of the catch liquid.FIG. 21 shows one embodiment of the weight check function of theinstruments of the present invention. An IPC mass container can bepositioned under the print head as close to the print head as possibleto minimize the loss of material due to vaporization. The IPC containercan contain a low vapor pressure liquid into which a predeterminedamount of the coating material can be dispensed from the print head.Once the print head material is dispensed into the low vapor pressureliquid in the IPC container the lid to the container is closed and thecontainer is transferred to a weigh station. Then a next patch tray canbe loaded and the coating of the microprojection array can continue. TheIPC container is placed on a balance for less than 50 second, optimallyless than 30 second and the IPC container can be removed from thebalance and prepared for the next print head weight check. The IPCcontainer need not be emptied as the difference in mass from oneweighing to the next will provide information as to the amount ofcoating material dispensed.

Printing a single drop from each nozzle of a two dimensional nozzlearray with a single piezo pulse onto a hydrophobic surface will checkthe alignment of each nozzle assuming the print head is as physicallyclose to the hydrophobic substrate as possible without disrupting thedrop (e.g. about 100 μm for a drop diameter of about 80 μm). The dropvelocity can be determined by moving the hydrophobic substrate whileprinting a single pulsed array. Printing separate arrays with thesubstrate moving sequentially in orthogonal directions and comparing theresults to those obtained with a static array can be used to assess dropvelocity and angle uniformity. If the velocity of the drop from thenozzle was less than that predicted the spacing between the drops wouldbe different. The tolerance could be determined in this fashion and apass/fail criteria could be applied to the device.

It is desirable to be able to monitor the characteristic of the fluid tobe dispensed from the high speed printing device. For example,monitoring the dose, heterogeneity, pH, protein content, viscosity ortemperature of the fluid at any point in time would ensure the qualityof the material to be dispensed. The approaches above with respect tothe weight of the drop could be applied to measure a variety ofcharacteristics of the solution such as those listed above. The solutioncharacteristic could either be measured inline or offline.

(d) Print Hold Function

Coating a pharmaceutical or biological material onto a device such as amicroprojection array presents unique challenges that are notencountered in a non-aseptic environment. Often time pharmaceuticals orbiologicals cannot be sterilized and thus must be manufactured in anenclosed controlled environment. Commercial print heads are required tobe periodically wiped to clean the head and to prevent wetting of thenozzle plate. Alternatively the print heads can be capped to prevent thenozzles from being clogged by dried printer ink if the print process ishalted. In aseptic printing of biological material neither of theseprocesses is desirable as there is a risk of contamination or thegeneration of particles that could clog the nozzles. The use of devicesto clean the print head and to interrupt printing in an asepticenvironment would complicate the process and would risk the integrity ofthe product. The methods of the present invention may, however, requirethat printing be halted for a period of time. The methods of the presentinvention provide a solution where wiping or capping the nozzles are notrequired and thus provide a contact-free method of printing or coatingwhich is compatible with aseptic or GMP manufacturing.

During the functioning of a print head the nozzle plate is filled withfluid and due to capillary action and a liquid-air interface a meniscusis formed at the nozzle exit. When exposed to the ambient environmentthe solvent in the fluid (e.g. water) evaporates from the meniscus andthe solute remains behind at the nozzle exit. In a static condition asthe solvent evaporates the solute accumulates at the nozzle exit therebyclogging the exit and impairing the ability to form liquid droplets fromthe nozzle during the jetting process. In certain industrial processesnot subject to GMP or aseptic conditions humectants may be added to thefluid which enables the solute to remain “soft”, even as the solventevaporates. The addition of humectants into pharmaceutical or biologicalmaterial is not desirable. It is also possible to actuate the piezomechanism in the print head to create oscillation of the meniscus whichbring solvent to the nozzle exit to refresh the meniscus and preventaccumulation of the solute at the nozzle exit. The degree of oscillationis affected by the thickness of the nozzle plate which is defined as thedistance from the nozzle exit to the first point that is discontinuouswith the internal profile of the nozzle. FIGS. 22A, B, C demonstratethree different nozzle geometries in which only FIG. 22C has acontinuous internal profile. The nozzles in FIGS. 22A and 22B havenozzle geometries with singularity points. FIGS. 23A and 23B arerepresentations of the nozzle plate and descender plate where there is adiscontinuous internal profile and a continuous internal profilerespectively. In most commercial print head geometries the continuousprofile of the nozzle is less than 100 μm. As a result, in cases wherethe meniscus oscillation is too high the contact line of the meniscusretracts into the nozzle plate internal profile and contacts thesingularity point leading to either stopped contact line movement ordisrupted contact line movement. When the contact line stops at singularpoints the concave shaped meniscus may retract so far into the nozzlethat before the centre of the meniscus oscillates back to the nozzle thenozzle is already closed. This results in the trapping of air inside thenozzle which can lead to the failure of dispensing of the fluid. Whenthe contact line is disrupted at the singular points within the nozzle aphenomenon called air-gulping occurs. The fractured meniscus contactline permits bubbles to penetrate the shoulder area above the nozzleleading to printing failure. As a result the space design for the piezowaveform is limited by the fact that the resulting meniscus contact lineoscillation within the nozzle plate thickness needs to have a lowboundary condition. In the nozzle plates of the present invention thenozzle plate can have a thickness of up to 1000 μm and the nozzle has acontinuous internal profile such that the meniscus contact line withinthe nozzle plate can move up and down with a total travel space of up to1000 μm without the risk of trapping bubbles. (See FIGS. 24A and 24B).

The piezo actuating waveform creates the meniscus oscillation. In oneembodiment a piezo unimorph structure is used to actuate the dropformation process. In this embodiment the piezo has a capacitive load offrom about 1 to 20 nF and is driven using a waveform with a peak to peakvoltage of about −200 V to +200 V. FIG. 25 demonstrates a waveform usedto enable meniscus oscillation. Unlike the waveform used to create dropformation, the meniscus oscillation waveform does not have a highvoltage of up to +200 V to create positive pressure inside the pumpingchamber to form droplets. Instead the meniscus oscillation waveformoperates mostly in the negative voltage range to create pressure wavesin the harmonic frequency of the meniscus oscillation. Depending on theacoustic speed of the fluidic being printed and the geometry of thenozzle plate, including the thickness, the waveform may take differentshapes. The frequency of running the waveform described in FIG. 25 maybe up to 1000 Hz. Another factor to be considered in the meniscusoscillation waveform is the slew rate which is the rate of changing fromone voltage value to another. In one embodiment of the meniscusoscillation waveform the slew rate should be above 150 V/μs. The highslew rate permits the rapid change in the piezo dimension and results ina sudden change in pumping chamber pressure. To achieve a high slew ratefor a capacitive load of up to 20 nF the piezo should have the followingcharacteristics: minimum slew rate of 150 V/μs, capacitive load of up to20 nF, peak current of 3 A, internal frequency of the waveform 100 Hzand global frequency of the waveform up to 1000 Hz. In some embodimentsof the printing device of the present invention the thickness of thepumping chamber is less than 0.3 mm. A thinner pumping chamber providesa lower pumping chamber fluid volume and thus less equivalent fluidiccapacitance and faster response to fluid pressure changes.

In the nozzle plates of the present invention the nozzle plate can havea thickness of up to 100 μm or 150 μm or 200 μm, or 300 μm, or 400 μm,or 500 μm, or 600 μm, or 700 μm, or 800 μm, or 900 μm or 1000 μm. In thenozzle plates of the present invention the nozzle plate can have athickness of between about 100 μm to 1000 μm, or from about 150 μm to1000 μm, or from about 200 μm to 1000 μm or from about 250 μm to 1000μm, or from about 300 μm to 1000 μm, or from about 400 μm to 1000 μm, orfrom about 500 μm to 1000 μm, or from about 600 μm to 1000 μm, or fromabout 700 μm to 1000 μm, or from about 800 μm to 1000 μm, or from about900 μm to 1000 μm, or from about 100 μm to 900 μm, or from about 150 μmto 900 μm, or from about 200 μm to 900 μm or from about 250 μm to 900μm, or from about 300 μm to 900 μm, or from about 400 μm to 900 μm, orfrom about 500 μm to 900 μm, or from about 600 μm to 900 μm, or fromabout 700 μm to 900 μm, or from about 800 μm to 900 μm or from about 100μm to 800 μm, or from about 150 μm to 800 μm, or from about 200 μm to800 μm or from about 250 μm to 800 μm, or from about 300 μm to 800 μm,or from about 400 μm to 800 μm, or from about 500 μm to 800 μm, or fromabout 600 μm to 800 μm, or from about 700 μm to 800 μm, or from about100 μm to 700 μm, or from about 150 μm to 700 μm, or from about 200 μmto 700 μm or from about 250 μm to 700 μm, or from about 300 μm to 700μm, or from about 400 μm to 700 μm, or from about 500 μm to 700 μm, orfrom about 600 μm to 700 μm, or from about 100 μm to 600 μm, or fromabout 150 μm to 600 μm, or from about 200 μm to 600 μm or from about 250μm to 600 μm, or from about 300 μm to 600 μm, or from about 400 μm to600 μm, or from about 500 μm to 600 μm, or from about 100 μm to 500 μm,or from about 150 μm to 500 μm, or from about 200 μm to 500 μm or fromabout 250 μm to 500 μm, or from about 300 μm to 500 μm, or from about400 μm to 500 μm, or from about 100 μm to 500 μm, or from about 150 μmto 500 μm, or from about 200 μm to 500 μm or from about 250 μm to 500μm, or from about 500 μm to 600 μm or from about 100 μm to 400 μm, orfrom about 150 μm to 400 μm, or from about 200 μm to 400 μm or fromabout 250 μm to 400 μm, or from about 100 μm to 300 μm, or from about150 μm to 300 μm, or from about 200 μm to 300 μm or from about 250 μm to300 μm, or from about 100 μm to 200 μm, or from about 150 μm to 200 μm,or from about 100 μm to 150 μm. The greater nozzle plate thicknessenables larger meniscus retraction and oscillation well above the nozzleexit (the descender section of the nozzle plate) without the problemsassociated with air gulping. The retracting and oscillation of themeniscus is so large that it enables full material mixing across theliquid-air interface. Full material mixing minimizes equalizes thechemical potential of all molecules at the liquid-air interface to thatin the liquid.

To prevent drying of the printing material a “tickling” function isprovided by the print head device which changes the piezo waveform toallow a drop of fluid material to be formed but not ejected from thenozzle and this function can provide a “bounce” of the meniscus layerfor a period of time. The geometry of the nozzle can be designed suchthat that a more thorough mixing of the fluid from the drop meniscuswhich permits the cessation of printing for an indefinite period of timeprovided the nozzles are purged prior to the next print cycle. The fluidthat is “tickled” can be recirculated within the nozzle geometry anddispensing of the fluid from the nozzles may be resumed by revertingback to the print waveform of the piezo.

The thickness of the nozzle plates in commercial print heads is lessthan 100 μm. The nozzle plates of the present invention may have athickness of from about 50 μm to about 5 mm. Preferably the nozzle plateis from about 200 μm to about 500 μm or from about 250 μm to about 500μm or from about or from about 300 μm to about 500 μm or from about 350μm to about 500 μm or from about 400 μm to about 500 μm or from about450 μm to about 500 μm. Increasing the thickness of the nozzle plateprovides the ability to create a high retracting meniscus movement intothe descender section of the nozzle plate without creating air gulping.In the devices of the present invention with increased nozzle platethickness the retracting meniscus motion is large enough to break downthe meniscus contact line at the nozzle thereby creating full fluidmaterial mixing across the entire meniscus surface. A thin nozzle plateas in those found in commercial print heads the contact line cannot befully broken down as this will introduce an air gulping problem and willprevent full fluid material mixing across the entire meniscus. Awaveform is required to create a negative pressure wave in the pumpingchamber and the pressure wave needs to be in harmonic frequency of themeniscus oscillation.

(e) Run Dry Print Head

In some uses of the print heads of the present invention theformulations of the fluid material that are coated onto the medicaldevices, such as the microprojection arrays, are expensive and it isadvantageous to minimize any loss of the material during priming andcoating. Liquid filling systems for syringes have a significant amountof residual fluid and require a certain level of fluid to maintainfilling thereby leading to loss of material. The devices of the presentinvention are designed such that the device can “run dry” and thusminimize the loss of material during the coating process. The print headdevices of the present invention provide monitoring of the return piezosignal and identification of the waveform changes that occur when thereis no fluid resistance between the piezo and the fluid interface. Thismonitoring and signal identification can detect when the fluid materialhas been depleted and thus printing can be halted. This method ofmonitoring and signal identification may also be used to detect partialor full blockage of the print head nozzle plate.

(f) Print Head/Nozzle Plate Manufacture

Current commercial print head nozzle plates are manufactured using anEDM process. This process provides nozzle plates with nozzle geometrywith a good finish, a high level of accuracy and low nozzle to nozzlevariation. The EDM process is time consuming and expensive and is not anefficient way to manufacture high level disposable print heads or nozzleplates. The print heads/nozzle plates of the present invention may becomprised of two plates in which holes are laser drilled and that arebonded together. The top plate has holes that are larger than those inthe bottom plate. The holes in the top plate can be on the order of fromabout 2 μm to 2000 μm, preferably between about 100μ to about 250 μm.The bottom plate from which the fluid is ultimately dispensed has holesthat correspond to those in the top plate, but the holes are smaller.The holes in the bottom plate should be on the order of from about 20 μmto about 200 μm or from about 30 μm to about 200 μm or from about 40 μmto about 200 μm or from about 50 μm to about 200 μm or from about 60 μmto about 200 μm or from about 70 m to about 200 μm or from about 80 μmto about 200 μm or from about 90 μm to about 200 μm or from about 100 μmto about 200 μm or from about 110 μm to about 200 μm or from about 120μm to about 200 μm or from about 130 m to about 200 μm or from about 140μm to about 200 μm or from about 150 μm to about 200 μm or from about160 μm to about 200 μm or from about 170 μm to about 200 μm or fromabout 180 μm to about 200 μm or from about 190 m to about 200 μm. Thetwo plates may be bonded together by the following including but notlimited to epoxy or diffusion bonding or laser welding such that thesmaller holes in the bottom plate are centred on the larger holes of thetop plate. The alignment and bonding of the two plates provides a finalshape that is capable of flow similar to that obtained with EDMmanufactured nozzle plates but the method is faster and less expensive.A combination of laser drilling and EDM manufacture may also be used tocreate the print heads/nozzle plates of the present invention.Alternatively there may be a single nozzle plate without a descenderplate. If there is only one plate below the pumping chamber plate, it iscalled nozzle plate. If however two plates are used to make the nozzleplate, then the top one is called descender plate and the bottom one iscalled the nozzle plate.

(g) Dry Priming

Commercial printers are designed to be pre-filled and pre-primed priorto shipping or use. The priming can be quite complex and requiredegassing filtration units or long periods under vacuum. Such methodsare not appropriate for pharmaceutical or biological materials, thus amethod that would permit priming in a dry sterile state minimizing fluidloss and enabling the manufacture of a pre-packed sterile unit would bepreferred. It is desirable to have a method where a dry sterile printhead can be filled with pharmaceutical or biological fluid materialwithout creating air bubbles that could affect the dispensing of thefluid. The print head could be filled with fluid without pre-priming orde-gassing. The fluid flows into a dry sterile print head andautomatically flows through without dispensing drops and eliminates anyair that could affect drop formation. This state is maintainedthroughout the printing period. In a preferred embodiment of the printhead of the present invention the low end of length of the fluid pathinside the print head is on the scale of less than 0.50 mm. The lengthof the fluid path inside the print head may be less than about 0.50 mmor less than about 0.45 mm or less than about 0.40 mm or less than about0.35 mm or less than about 0.30 mm or less than about 0.35 mm or lessthan about 0.20 mm or less than about 0.15 mm or less than about 0.10 mmor less than about 0.05 mm. The length of the fluid path inside theprint head may be about 0.05 to 0.50 mm, or about 0.05 to 0.45 mm orabout 0.05 to 0.40 mm or about 0.05 to 0.35 mm or about 0.05 to 0.30 mm,or about 0.05 to 0.25 mm or about 0.05 to 0.20 mm or about 0.05 to 0.15mm or about 0.05 to 0.10 mm, or about 0.10 to about 0.50 mm or about0.10 to 0.45 mm or about 0.10 to 0.40 mm or about 0.10 to 0.35 mm orabout 0.10 to 0.30 mm, or about 0.10 to 0.25 mm or about 0.10 to 0.20 mmor about 0.10 to 0.15 mm or about 0.15 to about 0.50 mm or about 0.15 to0.45 mm or about 0.15 to 0.40 mm or about 0.15 to 0.35 mm or about 0.15to 0.30 mm, or about 0.15 to 0.25 mm or about 0.15 to 0.20 mm or about0.20 to about 0.50 mm or about 0.20 to 0.45 mm or about 0.20 to 0.40 mmor about 0.20 to 0.35 mm or about 0.20 to 0.30 mm, or about 0.20 to 0.25mm or about 0.25 to about 0.50 mm or about 0.25 to 0.45 mm or about 0.25to 0.40 mm or about 0.25 to 0.35 mm or about 0.25 to 0.30 mm, or about0.30 to about 0.50 mm or about 0.30 to 0.45 mm or about 0.30 to 0.40 mmor about 0.30 to 0.35 mm or about 0.35 to about 0.50 mm or about 0.35 to0.45 mm or about 0.35 to 0.40 mm or about 0.40 to about 0.50 mm or about0.40 to 0.45 mm or about 0.45 to 0.50 mm. Capillary force dominates thewetting behaviour of the three-phase interphase (air-liquid-solid) ofthe fluid at these dimensions rather than gravitational hydrostaticpressure. The wetting behaviour consists of a moving air-liquid-solidcontact line. In an idealized case the contact line will move in such afashion that the line occupies the entire space of a fluid path and thusdoes not trap any air. For example, the liquid appears to push out allof the air during the filling of the dry print head. In a typicalcommercial print head there is one liquid inlet for the ink to fill theprint head and there are multiple outlets for the air to escape. Thesemultiple outlets are the jetting nozzles which each has its own path toconnect with the liquid inlet. The dimension of the individual fluidpath length is on the order of less than 0.5 mm. Applying back pressurepushes the fluid into the print head inlet allows the nozzle to beprimed such that the nozzles are filled with fluid without air bubblesin the pumping chambers. In the print heads of the present inventioneven though the lower end of range for the fluid path length is lessthan 0.5 mm the upper range of the dimension is up to about 20 mm whichis the pumping chamber dimension. The moving contact line in such a highaspect ratio geometry only in one direction is dominated by thecapillary force. In the print heads of the present invention the liquidflows into the pumping chamber from inlet channels. The number of inletchannels can be 1 or 2 or 3 or 4 or 5 or 6 or 7 or 8 or 9 or 10. Duringthe formation of the contact line inside the pumping chamber, dependingon the liquid flow rate of each individual channel, the resulting liquidcontact line may form any shape. Also, for the same reason, the pumpingchamber liquid filling process accompanied with the moving contact linedoes not rely on any specific mechanism but the random result of amultiplicity of factors including channel flow resistance, surfaceenergy heterogeneity, and local surface topography. This issue iscompounded in the print heads of the present invention as the twodimensional nozzle array has multiple outlet channels connected thepumping chamber. The outlets are designed to facilitate recirculation ofthe printing fluid through the pumping chamber to facilitate fluidmixing and reduce the settling of any materials dissolved or suspendedin the fluid. As a consequence of this setup while the liquid contactline moves one outlet channel, that which has the lowest resistancepath, will be reaches prior to the others. The channel that is reachesfirst permits the fluid to leave the pumping chamber through thisoutlet. As a result the pumping chamber is not completely filled withthe fluid and has air bubbles in the chamber. This issue may be solvedby de-gassing the fluid and recirculating the de-gassed fluid throughthe pumping chamber to dissolve trapped air bubbles, but this processadd time and cost and increased process and device complexity. Moreover,it is not desirable to de-gas pharmaceutical or biological material asit may cause degradation. Application of a vacuum to the fluid is alsoan option but does not provide a simple and inexpensive result. Finally,the issue could be addressed by vacuuming the print head, but this maylead to boiling the fluid which is also not desirable. Therefore, inpreferred embodiments of the print heads of the present invention thereis a single channel for fluid to enter the pumping chamber as well as asingle channel for fluid to exit the pumping chamber. Such a designeliminates the competition of fluid entering and exiting the pumpingchamber and results in a decrease in air entrainment. In addition, inpreferred embodiments of the print heads of the present inventionbetween the entering and exiting openings of the pumping chamber allboundaries of the pumping chamber plate around the nozzles have airvents to prevent the contact line from stalling.

(h) PZT Signal Generation

The waveform supplied to drive the PZT (Piezo) acts on the fluid anddetermines the characteristics of the dispensed fluid drops. Drop sizeis typically 120 pL, a nozzle array is typically 2,500 to 7,500 nozzlesper cm². The uniformity of drop, drop shape and size, the elimination ofsatellite drops, the ability to manipulate the fluid interface(meniscus) and therefore the ability to halt printing by oscillation ofthe meniscus are all controlled by this signal. Two examples of PZTdrivers are shown in FIGS. 26 and 27. PZT driver based on amplifier ApexMicrotechnology PA96 provides excellent high-speed control of the PZTwith up to a 250V/μs slew rate and a maximum voltage of ±140150V. PZTdriver based on amplifier Apex Microtechnology PA96 provides slightlylower performance in terms of speed and distortion, but has superiorpower dissipation. The PA79 amplifier is not able to provide enoughcurrent to drive the piezo element therefore the output is boosted byadding a pair of bipolar transistors. This circuit can be miniaturizedinto a small enough footprint as to be included in the print headassembly.

(i) PZT Signal Feedback

A controlled signal is generated to drive the PZT and generate drops atthe nozzle interface, as the PZT returns to its rest position a secondreturn signal waveform is generated. The waveform can be interrogated todetermine if the system is running properly. For example, if there is nofluid in the pumping chamber, or if entrapped air is present or if thenozzles blocked monitoring the return signal can determine the problemand appropriate actions can be taken.

Signal feedback can be achieved with the use of an RLC meter to connectdirectly to the PZT. For example, a 12.5 kHz sine wave can be sent tothe PZT. Under such a sine wave, the print head oscillates, generatesfriction, and loses heat. The PZT itself as a sensor senses the heatloss, creating a feedback to the RLC meter, i.e., ESR value. However, ifa bubble is present in the pumping chamber, the energy loss issignificantly higher. The ESR value with and without the bubbleexistence will be significantly different. If the system were purely acapacitive load, the phase shift of the sine wave signal would be 90degrees, but since it is not a pure capacitive load, the signal will beclose to 90 degrees. However, if the bubble exits, the shift will befurther away from 90 degrees. Alternatively, a second small diameterthin section “sensitive” PZT can be mounted inside the main PZT whichhas a doughnut-like shape. The inner PZT is not driven but records thereturn wave profile that is monitored for fault conditions. (See FIG.28).

Sterility and cleanliness are important in using inkjet technology tocoat pharmaceutical formulations onto devices such as microprojectionarrays. Thus, it is important that each component of the print head thatcomes into contact with the pharmaceutical formulation be made ofbiocompatible and sterilizable materials such as, but not limited to,stainless steel, glass, Teflon and nylon. Biologic materials cannot beterminally sterilized thus the final manufacturing process prior topacking must be conducted in a controlled “clean” environment. This isdone within the confines of an isolator that provides a high level ofenvironmental control. All equipment in this space must conform tostrict manufacturing and regulatory guidelines.

As described above, printhead devices of the present invention may haveone or more components that are disposable. For example, the printheaddevice may be constructed such that the piezoelectric stack actuator isre-usable while the pumping chamber and/or the nozzle plates are/isdisposable. The printhead device as a whole may be disposable. Tomaintain an aseptic environment the print head may need to be pre-primedwith a fluid prior to sterilization which minimizes the process requiredto set up the production process. A priming fluid may be similar to theprinting fluid with the exception that it may not contain the activebiological agent (i.e., vaccine). The purpose of the priming fluid is tofully wet the internal surfaces of the fluidic channels and maintainthis bubble free state until the active printing fluid is initiated. Onepriming fluid that may be used is water for injection (WFI).Sterilization can be performed in a number of ways that are known bythose skilled in the art of Pharmaceutical sterilization processes.These methods would typically include (but are not limited to): gammairradiation, ethylene oxide, aldehyde-based sterilants, and vaporizedhydrogen peroxide.

The print head devices of the present invention may be provided inaseptic packaging. The entire print head or a sub-assembly of the devicemay be supplied in sterile packaging where the print head is filled witha priming solution as described above. In preferred embodiments theprint head would not contain a priming solution as it is difficult tovalidate the complete removal of priming fluid residue prior toprinting. It would also be difficult to determine the effect of primingfluid residue on the dispensed formulation. The print head devices arethen removed from the packaging inside an aseptic enclosure. The printheads are mounted in position and supply lines from the bulk solutionfeed system are connected to the supply ports on the print head. If apriming solution is used a purge cycle can be implemented to prime thesolution to be delivered to the substrate (e.g. vaccine solution to themicroprojections on the microprojection array). In the case of a dryprinthead, purging is not required to prime the printer. In other wordsno fluid needs to be ejected during the priming process as this savesfluid and reduces the risk of machine contamination. A test cycle maythen be run by dispensing solution onto a target. A vision system mayinspect the test cycle to ensure alignment and positional tolerances aremet. For example, if the printhead is located on top of a non-porouspolymer substrate and the printhead is actuated for 10 times then in anideal case, 10 droplets will be dispensed from each nozzle onto thesubstrate. A line scanning camera would then scan through the substratewhere the droplets are printed. The scanned image could be analyzed toidentify 1) how many nozzles are firing, 2) positioning error (x-, y-,and rotational). The relative position of the line scanning camera andthe substrate is calibrated prior to above described process. The linescanning camera could be driven by a 1-D translational stage, during thescanning process. Once initiated, the print head will run continuouslyat an idle dispense to prevent drying at the nozzle tips. The print headmay periodically run a purge/clean cycle. In normal usage themanufacture of coated microprojection arrays would be per batch where abatch is a single feed lot of solution material (e.g. vaccine) andserial numbers for the print heads used in manufacture. The print headsmay be single use.

FIG. 29 shows one embodiment of a high speed single print head coatingdevice which comprises an X, Y stage on which microprojection arrays canbe mounted, a fiducial camera with LED light, a Z stage to which arotational print head is attached. The entire device can be mounted on abase (e.g. granite base) to ensure stability. The translational stage ispositioned below the coating height to minimize contamination viaparticulates generated by the stage movement. The stage has a positionalaccuracy of +/−1 μm and can travel of speeds up to 500 mm/s with anacceleration of 5000 mm/s². The design has been optimized such thatlaminar air flow is optimized to further reduce the risk of particulatesinterfering in the coating process. While the prior art describes MAPdesigns, the current technology fails to meet the stringent requirementsfor the high-throughput manufacturing in an aseptic manner at low-cost.For instance, seasonal vaccination for influenza requires an asepticmanufacturing throughput of 50 million units in 3 months (=approx. 23000units per hour). Fulfilling these numbers economically while assuringsafety and economic viability requires some innovation in how theproduct is packaged, assembled, presented as an input in the asepticmanufacturing machine, fast and accurately coated, and the wastegeneration, in general but also more precisely in the asepticenvironment. In order to coat the microprojection arrays in acost-effective manner, a high-throughput coating system would provide acomplete system control and verification of real time performance ofcoating a large number of microprojection arrays at high speed. For sucha high throughput system it may be necessary to use more than a singleprint head device. Such a high throughput device could utilize two orthree or four or five or six or seven or eight or nine or ten or moreprint heads.

(j) Patch Alignment

Misalignment of the target substrate can lead to a lack of efficacy ofthe substrate and can cause the coating material to be wasted. Onemethod for aligning the target substrates, notably microprojectionarrays, uses computer vision, image processing and custom sortingalgorithms to establish the location data for each microprojection on amicroprojection array. The data acquired is used to control precisemovement coordinates to various motor controllers which use thesecoordinates to perform minute adjustments such that the microprojectionarray is oriented to maximize the coating by the nozzles. Theseadjustments are unique from microprojection array to microprojectionarray and permit the print head to be orthogonal to each microprojectionarray on a consistent basis regardless of any misalignment or rotationthat may have been introduced as the microprojection array is loadedinto the printing device.

(k) Patch Mats

As described above, the instruments, devices and methods of the presentinvention need to provide high throughput solutions for coating anddelivering microprojection arrays. This includes having the patches thatwill be coated in a format where they can be coated and transportedeasily. One of the ways to provide patches that are in a more commercialproduction friendly form is to interconnect the individual MAP's intocompact mats that can be further stacked into a single compact body thatrequires minimal packaging. The mats can be individually manipulated inthe aseptic environment, more precisely the mat can be coated as oneunit thereby minimizing the instrument footprint, while presenting theMAP already aligned to the printing heads. This aspect of the presentinvention provides a means to obtain such in-plane cohesion of thepatches, while allowing slight individual freedom of movement of thepatch out of plane. This format enables each patch to be perfectly matedto the coating base. The patches can be individually detached from themat by a pick-and-place robot. Some embodiments of the mat formatprovide designs which minimal gaps between patches that preventover-spraying of the printing heads onto the coating base and furthercontamination of the next mat.

The MAP design permits the patches to be connected as a mat of partswhich provides: cohesive mat allows for the most compact transportvolume; reduced risk of particulate generation during transport andhandling; eliminates the need for complex support structures andexternal packing (Syringe tubs); MAP's handled through manufacturing inbulk as a mat rather than individual parts and a cohesive mat structureprotects the coating machine contact parts from contamination from printhead satellite drops. FIGS. 30-34 provide various embodiments of the matformat for the patches of the present invention. FIG. 30 shows anembodiment with a cohesive design featuring out-of-plane plane insertiondove tail connectors for the mat cohesion. FIG. 31 shows an embodimentwith a cohesive design featuring out-of-plane plane insertion connectorsfor the mat cohesion, and cross shaped ended spigot to stack the mats.FIG. 32 shows an embodiment with a cohesive design featuring in-planefriction fit connectors for the mat cohesion, and cross shaped endedspigot to stack the mats. FIG. 33 shows an embodiment with a strongcohesion of the mats in a compact stack is achieved with a hexagon shapeand through spigots. FIG. 34 shows an embodiment without guiding shaft(spigot), using instead in-plane friction fit connectors.

The mats of the present invention may also take the form of designs inwhich there is not a physical interlocking of the individual patches butrather the patches are simply butted against one another as shown inFIGS. 35-37. Patches form tiles that can be stacked to form a verycompact block for transport and handling (FIG. 37). The final packedform would have a moulded tray for a top and bottom cover, shrinkwrapped in polyethylene or similar.

With the array face down the external packaging and bottom cover traymay be removed for inline sterilization. Once sterilized the 1st layerof 100 patches are picked up by a vacuum plate that picks up 100patches. The vacuum plate is then placed under the print head with theprojections facing up. The patches are presented to the print head onthis vacuum plate with no visible gaps in between the patches otherwisea disposable single use tray or cover/ liner would be needed to preventcontamination from “overspray” touching the next load for coated.Following coating the whole vacuum plate with coated patches may beremoved to a quality control station and the removed for insertion intothe patch applicators. Patches may be removed by a system of pneumaticpins positioned below the vacuum plate that enable the patches to bepushed up in any order from the array. The vacuum trays are thenreturned for the next pick up. In one embodiment the stack of 10,000patches would be ˜300 mm high by 100 mm square.

(l) Fluid Reservoir

As described above the need for aseptic/sterile conditions for thebiological coating of the microprojection arrays is of importance in thepharmaceutical field. Having a disposable method of providing fluid tothe printer head would provide flexibility in providing aseptic/sterilematerial for coating the microprojection arrays. In one embodiment thefluid to be dispensed by the print head is provided by an integratedsupply or feed container that would be part of a print head device. Analternative embodiment would include an external fluid source that isnot integral to the print head device but rather is remote to the deviceand fluid can flow from the reservoir to the print head by a variety ofmeans including a series of tubes.

The base section of the printer body has embedded in it the controlsoftware and pressure sensing for the fluid control. Power andconnection to the main coating and assembly machine may be accomplishedthrough the spring loaded electrical contacts.

The fluid flow from the fluid reservoir to the print head may becontrolled in a variety of ways. In one embodiment the fluid iscontrolled by on board fluid pumping. FIG. 38 shows one embodiment of anintegrated fluid reservoir that is connected to the print head (3830).In this embodiment the reservoir is a bio processing bag which iscontained in a injection moulded polymer cover (3831). The fluid levelof the fluid in the bioprocessing bag can be seen through a transparentwindow (3832) in the cover which connects the bioprocessing bag to thebody of the printer. A bar code/ID label (3833) may be attached to thecover such that the unit may be tracked. The printer dock (3834) is partof the final coating and assembly device and the connection point to theprinter.

FIG. 39 shows another embodiment of the integrated fluid reservoirwithout a cover to envelope the fluid reservoir. In this embodiment thereservoir is a bioprocessing bag (3935) to which a fluid level window(3932) is welded. Otherwise similar reference numerals to those used inFIG. 38 are used to denote similar features, albeit increased by 100.

FIGS. 40A and 40B show a detailed perspective of this embodiment of thefluid reservoir. The fluid reservoir may have a sterile connector (4041)to connect the fluid reservoir (4040) to an outside source of fluid. Thereservoir may have a sampling port (4042) where the fluid can be sampledand a vent (4043). In addition the reservoir (4040) may have aperistaltic recirculation loop (4044) such that the fluid can berecirculate to maintain homogeneity. A clear moulded fluid level window(4032) may be attached via a weld (4036) to the reservoir (4040) toprovide a window for monitoring the fluid level within the reservoir,with a hole (4037) being provided to facilitate connection. The windowcan include a rim (4038), which facilitates connection to the printhead.The reservoir has pressure control and can be vented to the ambientatmosphere. The injected moulded main body may contain embeddedelectronics, pressure sensors and firmware.

In this embodiment the printer may rotate in both directions to permitindividual alignment of the printer head to each patch. A connectiondock rotates within the mounting arm. FIG. 41 is a schematic figure ofone embodiment of the integrated fluid reservoir interfacing with theprint head. Magnetic retainers (4151) hold the device in place and theflow channels (4152) redirect laminar airflow. The printer plate (4153)and the nozzle head (4154) are at the bottom of the device. Acommunications/electric port (4155) is provided to allow the printheadto be powered and controlled. FIG. 42 is a schematic of the printerconnection (4261) which rotates within a printer mounting arm (4234) toalign the print head nozzle with the patch and X, Y stage. The connectorhas location magnets (4263), an engagement ramp andcommunications/electric port (4264) to facilitate connection of theprinthead, and alignment of the magnets and communications ports.

In another embodiment the fluid is controlled by a fluid pump housed inthe mounting arm (4334) of the printer operating exposed flexible tubing(4371) from the printer (FIG. 43). FIG. 44 shows an embodiment of theexternal reservoir which may contain an electromagnetic array (4472) forstirring fluid. Mounting re-useable non-contact pumps in the mountingarm is less expensive but not as ergonomic as having the pump(s) in themoulded body of the printer. However the cost of a non-contact pump,such as a peristaltic or solenoid pump may be expensive for a disposableitem.

A system for controlling operation of the printhead is shown in FIG. 45.In broad terms, the system includes the disposable printhead system, ajetting control system, which controls operation of the printhead, andan ancillary system, such as a computer system or similar, whichsynchronizes operation of the printhead with positional control of thepatches.

In this example, the printhead system includes a reservoir 4540, such asa bioprocess bag, coupled to the printhead 4530 via feedlines 4571. Arecirculation line 4544 is provided to allow fluid to be recirculatedthrough the reservoir 4540 to prevent stagnation, and hence coagulationof fluid.

Flow through the feedlines 4571, 4544 is induced by feed andrecirculation pumps 4581, 4582, which are typically peristaltic pumpsincluding a drive and pump wheel, and which form part of the jettingcontrol system. The feed and recirculation pumps 4581, 4582 are drivenby signals from respective pump speed controllers 4583, 4584, which arein turn coupled to a microcontroller 4585, which coordinates operationof the jetting control system. The microcontroller 4585 receivespressure sensors from a pressure sensor 4586 in the feedline 4571,allowing this to be used to control the feed pump 4581.

The microcontroller 4585 is also coupled to a sensor 4587, which sensesbar code/ID label 4533, allowing the microcontroller 4585 to determinean indication of the fluid being dispensed. This is typically used toaccess control parameters, used in controlling operation of the pump,for example defining re-circulation requirements, required pressures,PZT operating parameters, or the like.

The microcontroller 4585 is coupled to a waveform generator 4588, whichgenerates a drive signal, that is amplified by amplifier 4589, beforebeing applied to the PZT element 4590, to cause the fluid to bedispensed.

In operation, signals are received from the ancillary system to triggeroperation of the microcontroller 4585, and the waveform generator 4588,so that the ancillary controller can cause fluid to be dispensed, oncethe patch and printhead are correctly aligned.

In a preferred method of controlling the fluid from the reservoir, thefluid is fed from the reservoir to the nozzle plate via the feedperistaltic or solenoid pump (4581). The pressure sensor (4586) betweenthe nozzle plate and the pump (4581) monitors the fluid pressure to thenozzle plate and engages (switched on) the pump (4581) when fluid isrequired. The pump is then disengaged (switched off) when the desiredlimit is reached. The pump can also be used to purge the head or thepump can create a negative pressure.

In certain embodiments mixing is used to maintain fluid homogeneity. Inone embodiment a magnetic stirrer built into the reservoir (bioprocessing bag) which is driven by a circular array of electromagnetswhich are embedded in the moulded printer body. An alternative method ofmixing is performed by a re-circulation pump (4582). The re-circulationpump is less expensive and an easier alternative as typically stirreroptions from suppliers are limited to large bag volumes.

One type of fluid reservoir (4540) is a bio-processing bag which ventsto ambient atmosphere via a 0.2 um filter. In a preferred embodiment thebio-processing bag has a sampling port. In some embodiments thereservoir has the following dimensions: Pre-filled Reservoir—110 mmwide×125 mm deep×250 mm tall. Remote Reservoir—90 mm dia×97 mm tall.

The advantages to using a fluid reservoir include sterility, ease ofuse, flexibility and reduced cost. A print head which is pre-filled withthe bio-processing bag can be shipped globally in cold chain storage.Once onsite outer packaging is removed and unit is passed into isolator,final layer packaging removed and the print head fitted to the dockfixed to the coating machine. Since the print head is supplied sterilewithout reservoir, the reservoir can be aseptically filled at thecoating site. Both the reservoir and the print head can be assembled onsite either aseptically or inside the isolator. The sterile printer maybe supplied configured for an external supply with supply linesattached. The print head may be brought into the isolator and the supplylines connected to a larger bio-processing supply or external tank.Multiple print heads can be connected to the same supply. Multiple printheads can be used in a large-scale coating and assembly machine orsingle print heads can be used for smaller desk top units.

(m) Manufacture of Device Using the Print Head

While many of the embodiments of the present invention relate to coatingmicroprojections on microprojection arrays, the print heads and printhead device and the high throughput instruments can be used for avariety of tasks including coating of objects other than microprojectionarrays. The print heads of the present invention may be used withcoating materials other than biologics or pharmaceuticals. Moreover, theprint heads and devices and instruments of the present invention may beused to make other devices using a variety of materials including butnot limited to polymers. The print heads of the present invention may beused to make microprojection arrays by dispensing polymers into moldsthereby enabling the manufacture of microstructures includingmicroprojection arrays.

(n) Coatings

In preferred embodiments the print head devices of the present inventioncoat the microprojections of the microprojection array with vaccineantigen formulations. The antigens may be derived from pathogenicorganisms which include, but are not limited to, viruses, bacteria,fungi parasites, algae and protozoa and amoebae. Illustrative virusesinclude viruses responsible for diseases including, but not limited to,measles, mumps, rubella, poliomyelitis, hepatitis A, B (e.g., GenBankAccession No. E02707), and C (e.g., GenBank Accession No. E06890), aswell as other hepatitis viruses, influenza, adenovirus (e.g., types 4and 7), rabies (e.g., GenBank Accession No. M34678), yellow fever,Epstein-Barr virus and other herpesviruses such as papillomavirus, Ebolavirus, influenza virus, Japanese encephalitis (e.g., GenBank AccessionNo. E07883), dengue (e.g., GenBank Accession No. M24444), hantavirus,Sendai virus, respiratory syncytial virus, othromyxoviruses, vesicularstomatitis virus, visna virus, cytomegalovirus and humanimmunodeficiency virus (HIV) (e.g., GenBank Accession No. U18552). Anysuitable antigen derived from such viruses are useful in the practice ofthe present invention. For example, illustrative retroviral antigensderived from HIV include, but are not limited to, antigens such as geneproducts of the gag, pol, and env genes, the Nef protein, reversetranscriptase, and other HIV components. Illustrative examples ofhepatitis viral antigens include, but are not limited to, antigens suchas the S, M, and L proteins of hepatitis B virus, the pre-S antigen ofhepatitis B virus, and other hepatitis, e.g., hepatitis A, B, and C,viral components such as hepatitis C viral RNA. Illustrative examples ofinfluenza viral antigens include; but are not limited to, antigens suchas hemagglutinin and neuraminidase and other influenza viral components.Illustrative examples of measles viral antigens include, but are notlimited to, antigens such as the measles virus fusion protein and othermeasles virus components. Illustrative examples of rubella viralantigens include, but are not limited to, antigens such as proteins E1and E2and other rubella virus components; rotaviral antigens such asVP7sc and other rotaviral components. Illustrative examples ofcytomegaloviral antigens include, but are not limited to, antigens suchas envelope glycoprotein B and other cytomegaloviral antigen components.Non-limiting examples of respiratory syncytial viral antigens includeantigens such as the RSV fusion protein, the M2 protein and otherrespiratory syncytial viral antigen components. Illustrative examples ofherpes simplex viral antigens include, but are not limited to, antigenssuch as immediate early proteins, glycoprotein D, and other herpessimplex viral antigen components. Non-limiting examples of varicellazoster viral antigens include antigens such as 9PI, gpII, and othervaricella zoster viral antigen components. Non-limiting examples ofJapanese encephalitis viral antigens include antigens such as proteinsE, M-E, M-E-NS 1, NS 1, NS 1-NS2A, 80%E, and other Japanese encephalitisviral antigen components. Representative examples of rabies viralantigens include, but are not limited to, antigens such as rabiesglycoprotein, rabies nucleoprotein and other rabies viral antigencomponents. Illustrative examples of papillomavirus antigens include,but are not limited to, the L1 and L2 capsid proteins as well as theE6/E7 antigens associated with cervical cancers, See FundamentalVirology, Second Edition, eds. Fields, B. N. and Knipe, D. M., 1991,Raven Press, New York, for additional examples of viral antigens.

Illustrative examples of fungi include Acremonium spp., Aspergillusspp., Basidiobolus spp., Bipolaris spp., Blastomyces dermatidis, Candidaspp., Cladophialophora carrionii, Coccoidiodes immitis, Conidiobolusspp., Cryptococcus spp., Curvularia spp., Epidermophyton spp., Exophialajeanselmei, Exserohilum spp., Fonsecaea compacta, Fonsecaea pedrosoi,Fusarium oxysporum, Fusarium solani, Geotrichum candidum, Histoplasmacapsulatum var. capsulatum, Histoplasma capsulatum var. duboisii,Hortaea werneckii, Lacazia loboi, Lasiodiplodia theobromas,Leptosphaeria senegalensis, Madurella grisea, Madurella mycetomatis,Malassezia furfur, Microsporum spp., Neotestudina rosatii, Onychocolacanadensis, Paracoccidioides brasiliensis, Phialophora verrucosa,Piedraia hortae, Piedra iahortae, Pityriasis versicolor, Pseudallesheriaboydii, Pyrenochaeta romeroi, Rhizopus arrhizus, Scopulariopsisbrevicaulis, Scytalidium dimidiatum, Sporothrix schenckii, Trichophytonspp., Trichosporon spp., Zygomcete fungi, Absidia corymbifera,Rhizomucor pusillus and Rhizopus arrhizus. Thus, representative fungalantigens that can be used in the compositions and methods of the presentinvention include, but are not limited to, candida fungal antigencomponents; histoplasma fungal antigens such as heat shock protein 60(HSP60) and other histoplasma fungal antigen components; cryptococcalfungal antigens such as capsular polysaccharides and other cryptococcalfungal antigen components; coccidiodes fungal antigens such as spheruleantigens and other coccidiodes fungal antigen components; and tineafungal antigens such as trichophytin and other coccidiodes fungalantigen components.

Illustrative examples of bacteria include bacteria that are responsiblefor diseases including, but not restricted to, diphtheria (e.g.,Corynebacterium diphtheria), pertussis (e.g., Bordetella pertussis,GenBank Accession No. M35274), tetanus (e.g., Clostridium tetani,GenBank Accession No. M64353), tuberculosis (e.g., Mycobacteriumtuberculosis), bacterial pneumonias (e.g., Haemophilus influenzae.),cholera (e.g., Vibrio cholerae), anthrax (e.g., Bacillus anthracis),typhoid, plague, shigellosis (e.g., Shigella dysenteriae), botulism(e.g., Clostridium botulinum), salmonellosis (e.g., GenBank AccessionNo. L03833), peptic ulcers (e.g., icobacter pyloriLegionnaire's Disease,Lyme disease (e.g., GenBank Accession No. U59487). Other pathogenicbacteria include herichia coli, Clostridium perfringens, Pseudomonasaeruginosa, Staphylococcus aureus and Streptococcus pyogenes. Thus,bacterial antigens which can be used in the compositions and methods ofthe invention include, but are not limited to: pertussis bacterialantigens such as pertussis toxin, filamentous hemagglutinin, pertactin,F M2, FIM3, adenylate cyclase and other pertussis bacterial antigencomponents; diphtheria bacterial antigens such as diphtheria toxin ortoxoid and other diphtheria bacterial antigen components; tetanusbacterial antigens such as tetanus toxin or toxoid and other tetanusbacterial antigen components, streptococcal bacterial antigens such as Mproteins and other streptococcal bacterial antigen components;gram-negative bacilli bacterial antigens such as lipopolysaccharides andother gram-negative bacterial antigen components; Mycobacteriumtuberculosis bacterial antigens such as mycolic acid, heat shock protein65 (HSP65), the 30 kDa major secreted protein, antigen 85A and othermycobacterial antigen components; Helicobacter pylori bacterial antigencomponents, pneumococcal bacterial antigens such as pneumolysin,pneumococcal capsular polysaccharides and other pnermiococcal bacterialantigen components; Haemophilus influenza bacterial antigens such ascapsular polysaccharides and other Haemophilus influenza bacterialantigen components; anthrax bacterial antigens such as anthraxprotective antigen and other anthrax bacterial antigen components;rickettsiae bacterial antigens such as rompA and other rickettsiaebacterial antigen component. Also included with the bacterial antigensdescribed herein are any other bacterial, mycobacterial, mycoplasmal,rickettsial, or chlamydial antigens.

Illustrative examples of protozoa include protozoa that are responsiblefor diseases including, but not limited to, malaria (e.g., GenBankAccession No. X53832), hookworm, onchocerciasis (e.g., GenBank AccessionNo. M27807), schistosomiasis (e.g., GenBank Accession No. LOS 198),toxoplasmosis, trypanosomiasis, leishmaniasis, giardiasis (GenBankAccession No. M33641), amoebiasis, filariasis (e.g., GenBank AccessionNo. J03266), borreliosis, and trichinosis. Thus, protozoal antigenswhich can be used in the compositions and methods of the inventioninclude, but are not limited to: plasmodium falciparum antigens such asmerozoite surface antigens, sporozoite surface antigens,circumsporozoite antigens, gametocyte/gamete surface antigens,blood-stage antigen pf 155/RESA and other plasmodial antigen components;toxoplasma antigens such as SAG-1, p30 and other toxoplasmal antigencomponents; schistosomae antigens such as glutathione-S-transferase,paramyosin, and other schistosomal antigen components; leishmania majorand other leishmaniae antigens such as gp63, lipophosphoglycan and itsassociated protein and other leishmanial antigen components; andtrypanosoma cruzi antigens such as the 75-77 kDa antigen, the 56 kDaantigen and other trypanosomal antigen components.

The print head devices and methods of using the print head devicesinclude the use of the print head device to deposit materials such aspolymers into molds for the manufacture of a variety of devicesincluding microprojection arrays. In one embodiment of the presentinvention the print heads of the present invention can deposit polymersor other materials into a pre-formed mold having depressions. Thepolymer material can be dispensed from the print head into the molds toform microprojections arrays. The polymer material includes but is notlimited to all thermoplastics and thermoset polymers such aspolystyrene, polyvinyl chloride, polymethylmethacrylate,acrylonitrile-butadiene styrene, and polycarbonate as well aspolypropylene, polybutylene terephthalate, polystyrene, polyethylene,polythermide, polyethylene terephthalate, and blends thereof.

Within this disclosure, any indication that a feature is optional isintended provide adequate support (e.g., under 35 U.S.C. 112 or Art. 83and 84 of EPC) for claims that include closed or exclusive or negativelanguage with reference to the optional feature. Exclusive languagespecifically excludes the particular recited feature from including anyadditional subject matter. For example, if it is indicated that A can bedrug X, such language is intended to provide support for a claim thatexplicitly specifies that A consists of X alone, or that A does notinclude any other drugs besides X. “Negative” language explicitlyexcludes the optional feature itself from the scope of the claims. Forexample, if it is indicated that element A can include X, such languageis intended to provide support for a claim that explicitly specifiesthat A does not include X. Non-limiting examples of exclusive ornegative terms include “only,” “solely,” “consisting of,” “consistingessentially of,” “alone,” “without”, “in the absence of (e.g., otheritems of the same type, structure and/or function)” “excluding,” “notincluding”, “not”, “cannot,” or any combination and/or variation of suchlanguage.

Similarly, referents such as “a,” “an,” “said,” or “the,” are intendedto support both single and/or plural occurrences unless the contextindicates otherwise. For example “a dog” is intended to include supportfor one dog, no more than one dog, at least one dog, a plurality ofdogs, etc. Non-limiting examples of qualifying terms that indicatesingularity include “a single”, “one,” “alone”, “only one,” “not morethan one”, etc. Non-limiting examples of qualifying terms that indicate(potential or actual) plurality include “at least one,” “one or more,”“more than one,” “two or more,” “a multiplicity,” “a plurality,” “anycombination of,” “any permutation of,” “any one or more of,” etc. Claimsor descriptions that include “or” between one or more members of a groupare considered satisfied if one, more than one, or all of the groupmembers are present in, employed in, or otherwise relevant to a givenproduct or process unless indicated to the contrary or otherwise evidentfrom the context.

Where ranges are given herein, the endpoints are included. Furthermore,it is to be understood that unless otherwise indicated or otherwiseevident from the context and understanding of one of ordinary skill inthe art, values that are expressed as ranges can assume any specificvalue or subrange within the stated ranges in different embodiments ofthe invention, to the tenth of the unit of the lower limit of the range,unless the context clearly dictates otherwise.

All publications and patents cited in this specification are hereinincorporated by reference as if each individual publication or patentwere specifically and individually indicated to be incorporated byreference. The citation of any publication is for its disclosure priorto the filing date and should not be construed as an admission that thepresent invention is not entitled to antedate such publication by virtueof prior invention.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that the various changes in form and detailsmay be made therein without departing from the scope of the inventionencompassed by the appended claims.

Throughout this specification and claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” or “comprising”, will be understood to imply the inclusionof a stated integer or group of integers or steps but not the exclusionof any other integer or group of integers. As used herein and unlessotherwise stated, the term “approximately” means ±20%.

It must be noted that, as used in the specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the context clearly dictates otherwise. Thus, for example,reference to “a support” includes a plurality of supports. In thisspecification and in the claims that follow, reference will be made to anumber of terms that shall be defined to have the following meaningsunless a contrary intention is apparent.

It will of course be realised that whilst the above has been given byway of an illustrative example of this invention, all such and othermodifications and variations hereto, as would be apparent to personsskilled in the art, are deemed to fall within the broad scope and ambitof this invention as is herein set forth.

1. A device for coating a substrate comprising: a) a piezoelectricactuator; b) a membrane plate; c) deformation clearance plate; d) arestrictor pumping chamber; and e) a nozzle plate.
 2. A device accordingto claim 1, wherein the piezoelectric actuator is activated by a signaland operably linked to the membrane plate such that when thepiezoelectric actuator is activated by the signal the membrane plate isdeformed through the deformation clearance plate such that the membraneplate contacts a fluid in the restrictor pumping chamber such that thefluid is pushed out of the restrictor pumping chamber and through aplurality of nozzles of the nozzle plate and onto the substrate.
 3. Thedevice of claim 1, wherein the piezoelectric device is bonded to themembrane plate to form a first subassembly and wherein the deformationclearance plate and restrictor pumping chamber and nozzle plate arebonded together to form a second subassembly and the first subassemblyand second subassembly are bonded together to form the device.
 4. Thedevice of any of claim 1, wherein the piezoelectric actuator is at leastone of: a) piezoelectric stack actuator; and, b) a piezoelectricunimorph actuator.
 5. The device of any of claim 1, further comprising ahousing that encases the piezoelectric actuator, membrane plate,deformation clearance plate, restrictor pumping chamber and nozzleplate.
 6. The device of any of claim 1, wherein the pumping chamberplate further comprises one or more restrictors.
 7. The device of any ofclaim 1, wherein the pumping chamber plate further comprises one or moreair venting facilities.
 8. The device of any of claim 1, wherein themembrane plate is about or less than 100 μm in thickness.
 9. The deviceof any of claims 1, wherein the deformation clearance plate is fromabout 20 μm to about 60 μm in thickness.
 10. The device of any of claims1, wherein the nozzle plate comprises nozzle plate holes from whichfluid is dispensed.
 11. The device of any of claims 1, wherein thenozzle plate includes a plurality of nozzles made in a two dimensionalarray.
 12. The device of claim 11, wherein the number of nozzles in thetwo dimensional array is between 500 to
 5000. 13. The device of any ofclaim 1, wherein a spacing between nozzles in the nozzle plate is fromabout 50 to about 500 micrometers.
 14. The device of any of claim 1,wherein the nozzle plate comprises venting holes.
 15. The device ofclaim 14, wherein the venting holes are less than 50 μm in diameter. 16.The device of any of claim 14, wherein the venting holes are not taperedand wherein the venting holes create high flow resistance.
 17. Thedevice of any of claim 14, wherein the venting holes are smaller indiameter than the nozzle holes.
 18. The device of any of claim 1,wherein the device further comprising a fluid reservoir.